11 65 040 Remove and install/replace high pressure exhaust turbocharger (small exhaust turbocharger) (M57T2-SCR)

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

Recycling:

Catch escaping engine oil with suitable auxiliary materials.

Observe country-specific waste disposal regulations.

NOTE: Troubleshooting on exhaust turbocharger.

Necessary preliminary tasks:

Remove acoustic cover at rear. See 13..... REMOVE THE ACOUSTIC COVERS (M57T2 WITH AND WITHOUT SCR) .
Remove AIR INTAKE SILENCER HOUSING .
Remove TRAILING LINK ON SPRING STRUT DOME .

IMPORTANT: In event of turbocharger damage:

Pressure pipes
Charge air cooler
Intake plenum

check the above for foreign bodies, damage and correct function, replacing if necessary.

Release banjo bolt (1) on exhaust manifold.

Tightening torque: 13 62 9AZ .

IMPORTANT: To ensure operational reliability, use stainless steel sealing washers.

Fig 1: Identifying Banjo Bolt On Exhaust Manifold

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Unlock and disconnect connector (1) on electropneumatic pressure converter.

Detach blue vacuum hose from vacuum unit (turbine control flap).

If necessary, disconnect red vacuum hose from vacuum unit (compressor bypass).

Fig 2: Identifying Electropneumatic Pressure Converter Connector

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Unlock and release connector (1) under vacuum reservoir of EPPT valve.

Fig 3: Identifying EPPT Valve Connector

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Release screws (1) on vacuum reservoir.

Tightening torque: 11 00 2AZ .

Unlock, detach and disconnect connectors (2, 3 and 4).

Release fuel differential-pressure sensor (5) from vacuum reservoir.

Tightening torque: 13 62 7AZ .

Unlock and detach all connectors.

Fig 4: Identifying Screws On Vacuum Reservoir

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Remove vacuum reservoir (1) from stud bolts (2).

Fig 5: Removing Vacuum Reservoir From Stud Bolts

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Feed out vacuum reservoir upwards and to side.

Fig 6: Removing Vacuum Reservoir

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Release screws (1 and 2) and remove vacuum reservoir carrier.

Tightening torque: 11 00 2AZ .

Fig 7: Identifying Vacuum Reservoir Carrier And Screws

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Unlock electronic changeover valve (1) from holder (2), slide forwards and remove from retaining plate.

Fig 8: Removing Electronic Changeover Valve From Holder

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Release screws (1).

Remove retaining plate (2).

NOTE: Picture shows vacuum unit removed (turbine control flap).

Fig 9: Removing Retaining Plate And Screws

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Release screws on heat shield (1).

Tightening torque: 11 00 2AZ .

Lift out heat shield.

Fig 10: Locating Screws On Heat Shield

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Release screw (1).

Tightening torque: 11 00 2AZ .

Detach clean air pipe (2) from low-pressure turbocharger towards front.

Fig 11: Identifying Clean Air Pipe And Screw

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Slacken nut (1).

Pull line clip from stud bolt.

Tightening torque: 11 00 2AZ .

Fig 12: Identifying Slacken Nut

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Detach engine oil pipe (1).

Tightening torque: 11 42 5AZ .

Detach engine oil pipe (2).

Tightening torque: 11 42 5AZ .

Unfasten hose clamp (3).

Tightening torque: 11 00 7AZ .

Release screw (4).

Tightening torque: 11 00 2AZ .

Release screws (5) and (6) from connecting pipe.

Tightening torque: 11 00 2AZ .

Fig 13: Identifying Engine Oil Pipe And Screws

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(E70 only)

Replace O-rings (1) on oil return line.

Fig 14: Identifying O-Rings On Oil Return Line

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Release bolts (1) through 180°.

Tightening torque: 11 00 2AZ .

Turn retaining plates (2) to side until compressor inlet pipe (3) to low-pressure turbocharger can be detached.

Installation note:

Replace O-rings.

Fig 15: Identifying Low-Pressure Turbocharger And Bolts

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Release bolts (1) through 180°.

Tightening torque: 11 00 2AZ .

Turn retaining plates (2) to side until compressor outlet pipe (3) to charge air cooler/connecting pipe can be detached.

Installation note:

Replace O-rings.

Fig 16: Identifying Charge Air Cooler/Connecting Pipe And Bolts

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Release screws (1).

Tightening torque: 11 65 1AZ .

Unfasten screws (2).

Tightening torque: 11 65 2AZ .

Remove exhaust turbocharger.

Installation note:

Clean sealing surfaces and replace gasket.

Apply a thin coating of copper paste to bolt thread.

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

Fig 17: Identifying Exhaust Turbocharger And Screws

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Release screws (1) on oil return pipe.

Tightening torque: 11 00 2AZ .

Installation note:

Replace beaded metal gasket.

Fig 18: Identifying Screws On Oil Return Pipe

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NOTE: Cover opening of manifold to prevent swarf from falling in.

IMPORTANT: Clean threads (1) prior to assembly with extension (2) and thread cutter (3)

Fig 19: Cleaning Threads Prior To Assembly

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Assemble engine.

Observe ARRANGEMENT of vacuum lines.

Perform check of vacuum control.

Check function of Digital Diesel Electronics.

Activities
Function structure

Power train

Diesel fuel electronics

Air mass system

Charging pressure control