11 65 024 Removing and installing/replace exhaust turbocharger for cylinders 4-6 (N54, N54T)

Necessary preliminary tasks

Remove both catalytic converters. See CATALYTIC CONVERTER FOR CYLINDERS 1-3 and CATALYTIC CONVERTER FOR CYLINDERS 4-6 .
Remove CHARGE AIR COOLER .
Drain COOLANT .
REMOVE coolant expansion tank.
Remove both vacuum reservoirs.
Remove right CHARGE-AIR DUCT .
Remove the ENGINE SUPPORT ARM on the right (not E60, 61)

Release screws (1).

Tightening torque 11 42 7AZ .

Installation note:

Replace gasket.

Release screw (2).

Tightening torque 11 42 8AZ .

Remove oil return pipe in direction of arrow.

Installation note:

Replace O-ring.

Fig 1: Identifying Oil Return Line Screws

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Release screws (1 and 2).

Tightening torque 11 53 10AZ .

Release coolant feed lines (3 and 4) if necessary with suitable pliers.

IMPORTANT: Do not place pliers on pipes. Risk of damage!

Installation note:

Replace O-rings.

Fig 2: Identifying Coolant Feed Lines And Screws

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Release screws (1).

Tightening torque 11 53 3AZ .

Remove feed line (2).

Installation note:

Replace O-ring.

Fig 3: Identifying Feed Line And Screws

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Release screw (1).

Tightening torque 11 53 9AZ .

Release coolant return pipe if necessary with suitable pliers.

IMPORTANT: Do not place pliers on pipes. Risk of damage!

Installation note:

Replace O-ring.

Fig 4: Identifying Screw

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Release screw (1).

Tightening torque 11 53 8AZ .

IMPORTANT: When detach coolant feed pipe (3), pay attention to linkage of vacuum unit (wastegate valve).

Risk of damage!

Release coolant feed pipe (3) if necessary with suitable pliers.

Release coolant return pipe (2) if necessary with suitable pliers and remove.

IMPORTANT: Do not place pliers on pipes. Risk of damage!

Fig 5: Identifying Coolant Feed Pipe, Coolant Return Pipe, And Screw

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Installation note:

Replace O-ring.

Release screws (1).

Tightening torque 11 65 2AZ .

Remove retaining plate (2).

Release screws (3 and 4).

Tightening torque 11 65 2AZ .

Fig 6: Identifying Retaining Plate And Screws

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IMPORTANT: Carefully swing out heat shields (2 and 3) in direction of arrow.

Risk of damage!

Remove heat shield (3) in direction of arrow.

Remove heat shield (2) in direction of arrow.

Fig 7: Removing Heat Shields

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NOTE: Coolant feed pipe (1) can be removed with heat shield (2).

Release screw (1).

Tightening torque 11 42 4AZ .

Detach oil feed line in direction of arrow.

Installation note:

Replace O-ring.

Fig 8: Detaching Oil Feed Line

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Release screws (1).

Tightening torque 11 65 3AZ .

Set holder (2) down on cylinder head cover.

Fig 9: Identifying Holder And Screws

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Detach vacuum hose from vacuum unit (wastegate valve).

Unscrew nuts (1).

Remove turbocharger towards bottom.

Tightening torque 11 65 1AZ .

IMPORTANT: Do not misuse linkage of vacuum unit (wastegate valve) for transportation.

Risk of damage!

Fig 10: Identifying Nuts

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Release screw (2).

Tightening torque 11 42 5AZ .

IMPORTANT: Where necessary, to release the oil feed line (3), do not place pliers on the pipe.

Risk of damage!

If necessary, release oil feed line (3) with suitable pliers at connection and remove.

Fig 11: Identifying Turbocharger, Oil Feed Line, And Screw

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Installation note:

Replace O-rings.

Installation note:

Replace graphite sealing rings (1).

Assemble engine.

Clear fault memory in DME control unit.

Check air intake system for leaks.

Observe DME instructions.