11 65 020 Removing and installing or replacing turbocharger (N57): Notes

Special tools required:

11 6 050 .

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

NOTE: Read notes on TROUBLESHOOTING ON THE TURBOCHARGER .

WARNING:

For turbocharger damage:

In order to avoid subsequent damage, the following notes and test steps must always be followed: see TURBOCHARGER DAMAGE DUE TO BLOCKED OIL SUPPLY LINES and TEST STEPS IN THE EVENTING OF TURBOCHARGER DAMAGE .

Necessary preliminary tasks:

Remove ACOUSTIC COVER .
Remove front SOUND INSULATION COVERS .
Draw off A/C SYSTEM .
Remove REINFORCEMENT PLATE .
Remove right PRESSURE PIPE .

Release screws (1).

Pull the refrigerant line (2) off.

Installation note:

Replace the sealing ring.

Tightening torque 64 53 5AZ .

Fig 1: Identifying Refrigerant Line And Screw

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Release screws (1).

Pull the refrigerant line (2) off.

Installation note:

Replace the sealing ring.

Tightening torque 64 53 3AZ .

Fig 2: Identifying Refrigerant Line And Screw

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Loosen the bolt (2) on the hydraulic unit.

Unclip rubber grommets (1 and 3).

Fig 3: Identifying Hydraulic Unit Bolt And Rubber Grommets

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Undo bolts (1) on sound muffler.

Fig 4: Identifying Sound Muffler Bolts

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Pull sound muffler (1) forwards off turbocharger.

Fig 5: Identifying Sound Muffler

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Disconnect plug connection (1) on actuator drive.

Release screw (2).

Unlock clip (3) in direction of arrow.

Pull off air intake hose (4) in direction of arrow.

Fig 6: Identifying Air Intake Hose, Clip, Plug Connection And Screw

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Release banjo bolt (1).

NOTE: Catch escaping engine oil in a suitable container.

Disconnect line (2).

Tightening torque 11 42 2AZ .

Installation note:

Clean sealing surfaces.

Fig 7: Identifying Banjo Bolt And Line

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Unfasten hose clamp (1).

Return line is also removed when turbocharger is removed.

If necessary, remount oil return line and replace gasket.

Fig 8: Identifying Hose Clamp

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Release screw (1) of clamp between diesel particle filter and turbocharger.

Installation note:

Clamp must be replaced after removal.

Tightening torque 18 31 2AZ .

Fig 9: Identifying Clamp Screw

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Release screws (1).

Remove holder (2).

Tightening torque 11 65 2AZ .

Fig 10: Identifying Holder And Screws

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Release screw (1).

Turn oil filler neck (2) in the direction of the arrow to stop.

Remove oil filler neck (2) towards top.

Fig 11: Turning Oil Filler Neck

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Press locking hooks (1) down.

Remove hose (2) for engine ventilation.

Fig 12: Identifying Engine Ventilation Hose And Locking Hooks

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Undo screw on V-strap clamp between turbocharger and exhaust manifold.

Tightening torque: 11 65 1AZ .

Fig 13: Identifying V-Band Clamp Ends

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Pull hydraulic unit to the side and Maneuver out/remove turbocharger (1) upwards in position illustrated.

Fig 14: Identifying Turbocharger

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Installation note:

Screw connection of V-band clamp is too loose.

If you can see a gap between the ends of the V-band clamp, release and then repeat the screw connection.

Tightening torque: 11 65 1AZ .

Fig 15: Identifying Gap Between Ends Of V-Band Clamps

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Installation note:

Screw connection of V-band clamp is too tight.

If the ends of the V-clip are positioned under each other, release and then repeat the screw connection.

Tightening torque: 11 65 1AZ .

Fig 16: Identifying Misalignment Of V-Band Clamp Ends

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Installation note:

Pay attention to retaining pin (1) when installing turbocharger.

Replace sealing ring (2).

Fig 17: Identifying Retaining Pin And Sealing Ring

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If necessary, replace turbocharger.

Release banjo bolt (1).

Installation note:

Tightening torque 11 42 2AZ .

Replace sealing rings.

Engine oil line must run obliquely along the housing (see illustration).

Fig 18: Identifying Proper Installation Position Of Engine Oil Pipe

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Assemble engine.

Observe diagnosis instructions.

Complete vehicle
Power train
Engine electrical system
Air supply
Charging pressure control