11 65 020 Removing and installing or replacing exhaust turbocharger (N47 D20 O1)

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: Before installing exhaust turbocharger, check the oil supply to the exhaust turbocharger and the oil return from the exhaust turbocharger for foreign bodies and oil sludging, clean if necessary.

Necessary preliminary tasks:

Remove INTAKE SILENCER HOUSING .
Remove acoustic covers on top and front. See 13..... REMOVE ACOUSTIC COVER (N47 D20 O/T1) .
Loosen V-Band washer DIESEL PARTICLE FILTER (diesel particle filter does not have to be removed).
Remove right PRESSURE PIPE .

Loosen screw on air intake hose (2).

Unlock clip (1) in direction of arrow.

Pull off air intake hose (2) in direction of arrow.

Fig 1: Pulling Air Intake Hose

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Release screw (1).

Fig 2: Identifying Screw

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Release screw (1).

Unfasten banjo bolt (2).

11 62 2AZ .

Place exhaust pipe (3) to one side.

Remove heat shield toward top.

Fig 3: Identifying Exhaust Pipe And Banjo Bolt

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

Installation note:

Replace steel sealing rings (1).

Fig 4: 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 5: Identifying Banjo Bolt

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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 6: Identifying Exhaust Turbocharger Return Line And Screws

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Release screw (1).

Unfasten screws (2).

Remove bracket (3).

Fig 7: Identifying Bracket And Screws

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Release bihexagonal bolts on exhaust turbocharger with special tool 11 6 050 .

Tightening torque: 11 65 1AZ .

Installation note:

Replace gasket.

Fig 8: Releasing Bihexagonal Bolts On Exhaust Turbocharger With Special Tool (11 6 050)

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

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

Use gripper (2) to remove bihexagonal bolt (1).

Fig 9: Removing Bihexagonal 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 10).

Fig 10: Identifying 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:

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