11 65 020 Removing and installing/replacing exhaust turbocharger (N47D20 K/U/O 1)

Special tools required:

11 6 050

WARNING: Risk of burning!
Only perform this repair work on an engine that has cooled down.

NOTE: Troubleshooting on exhaust turbocharger.

IMPORTANT: For exhaust gas turbocharger damage:
BE SURE TO FOLLOW THE INSTRUCTIONS .

Pressure pipes
Charge air cooler
Intake plenum

must be checked for foreign bodies, damage and correct function.

Necessary preliminary tasks:

REMOVE ACOUSTIC COVERS .
Loosen V-Band washer DIESEL PARTICLE FILTER (diesel particle filter does not have to be removed).
Release PRESSURE PIPE at right from exhaust turbocharger and set aside.
Remove clean air pipe . See 13 71 150 REMOVING CLEAN AIR PIPE (N47 D16/20 K/U/O/T 1) or 13 71 150 REMOVING CLEAN AIR PIPE (N47 D20 O 1 WITH SCR) .

Release screw (1).

Unfasten banjo bolt (2).

13 62 7AZ .

Place exhaust pipe (3) to one side.

Remove heat shield toward top.

Fig 1: Identifying Exhaust Pipe, Banjo Bolt And Screw

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Release screw (1).

To remove heat shield, release connectors of oxygen sensors from support.

Fig 2: Identifying Heat Shield And Screw

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IMPORTANT: Use steel sealing rings (1) only.
Risk of damage!

Installation note:

Replace steel sealing rings (1).

Fig 3: Identifying Steel Sealing Rings

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Release banjo bolt (1).

NOTE: Catch escaping engine oil in a suitable container.

Disconnect line (2).

Tightening torque 11 42 3AZ .

Installation note:

Clean sealing surfaces.

Fig 4: Identifying Banjo Bolt

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Release screw (1) from exhaust turbocharger and take off holder (2 positive battery cables).

Fig 5: Identifying Exhaust Turbocharger And Screw

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Disconnect plug (1) from turbocharger adjustment.

Fig 6: Identifying Turbocharger Plug

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Unfasten hose clamp (3).

Tightening torque: 11 00 7AZ .

Remove return line (2) from the removed exhaust turbocharger.

Release screws (1).

Installation note:

Replace gasket.

Fig 7: Identifying Return Line And Hose Clamp

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Release screw (1).

Unfasten screws (2).

Remove bracket (3).

Fig 8: Identifying Bracket And Screws

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Release bi-hexagonal bolts on exhaust turbocharger with special tool 11 6 050 .

Tightening torque: 11 65 1AZ .

Remove exhaust turbocharger upward.

Installation note:

Replace gasket.

IMPORTANT: To avoid damaging the threads and prevent exhaust turbocharger leaks, insert mounting bolts in 1/2 turns simultaneously.

Fig 9: Releasing Bi-Hexagonal Bolts On Exhaust Turbocharger

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NOTE: High-strength bolts are not magnetic and cannot be removed with a magnet.

Use gripper (2) to remove bi-hexagonal bolt (1).

Fig 10: Removing Bi-Hexagonal Bolt

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If the exhaust turbocharger is replaced, the engine oil pipe (2) must be modified.

Release banjo bolt (1).

Installation note:

Tightening torque 11 42 3AZ.

Replace sealing rings.

Oil line (2) must run obliquely along the housing (see Fig 11).

Fig 11: Identifying Engine Oil Pipe And Banjo Bolt

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Assemble engine.

IMPORTANT: Grease the thread on the exhaust turbocharger with the ASSEMBLY PASTE 4.2 .
To avoid damaging the threads and prevent exhaust turbocharger leakage, insert retaining screws in 1/2 turns simultaneously until they are flush.
Release all bolts again by a 90° turn.
Follow sequence of exhaust turbocharger screw connections:

Fasten V-band clip 18 31 1AZ .
exhaust turbocharger screw connection at the exhaust manifold 11 65 1AZ .
Crankcase holder on the exhaust turbocharger 11 00 2AZ .