11 65 022 Removing and installing/replacing turbocharger for cylinders 1-3 (S55)

Special tools required: 

• 00 6 100

Necessary preliminary work: 

• Drain ENGINE OIL .
• Drain COOLANT .
• Remove both catalytic converters. Refer to 18 32 050 REMOVING AND INSTALLING/REPLACE CATALYTIC CONVERTER FOR CYLINDERS 1-3 (S55) and 18 32 060 REMOVING AND INSTALLING/REPLACE CATALYTIC CONVERTER FOR CYLINDERS 4-6 (S55) .
• Secure ENGINE IN INSTALLATION POSITION .

Release screws (1) from both engine mounts.

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Lift engine with special tool 00 6 100 by dimension A to 25 mm.

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Unfasten screws (2).

Remove engine support arm.

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Release screws (1).

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Disconnect coolant line (3) from auxiliary coolant pump.

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Release screw (1).

Remove coolant feed line (2) downwards.

Tightening torque: 11 53 4AZ .

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Release screw (1).

Tightening torque: 11 53 4AZ .

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Release screw (1).

Tightening torque: 11 53 5AZ .

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Replace coolant line (1 and 2) O-rings (3).

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Release screws (1).

Tightening torque: 11 42 7AZ .

Release oil return line (2) in direction of arrow.

Installation note: 

Replace O-ring.

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Release screw (2).

Tightening torque: 11 42 4AZ .

Release oil feed line (3).

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Release screws (1).

Tightening torque: 11 65 2AZ .

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Release screws (1).

Tightening torque: 11 65 2AZ .

Remove heat shield (2) towards top.

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Rotate heat shield (1) in direction of arrow.

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Remove heat shield (1) upwards in direction of arrow.

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Release nuts (10 to 1).

Remove turbocharger towards top.

Risk of damage! 

When replacing the exhaust turbocharger: 

Release screw (1).

Tightening torque: 11 42 5AZ .

Release and remove the oil feed line (2) on the connection.

Installation note: 

Replace O-rings.

Illustration: Cylinders 4-6

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Installation: 

Replace exhaust manifold gasket (1).

Pay attention to the dowel pin (see arrow in illustration).

Stud bolts must be inserted with a screw locker (Loctite 243).

Tighten stud bolts with 15 Nm.

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Join centering nuts (1) AF 11 with 5 Nm.

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Provide drill (1) with 1.5 mm.

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Position exhaust turbocharger (A).

Insert drill (9) 1.5 mm between stud bolts and exhaust manifold (see illustration).

Join all nuts in sequence (1 to 9) to 5 Nm.

Remove drill (9).

Coat all stud bolts with engine oil.

Be sure to observe tightening sequence.

Join centering nut (1) AF 11 with 12 Nm  .

Join nuts (2 to 10) AF 10 with 12 Nm  .

Attach centering nut (1) with 90°  angle of rotation.

Tighten nuts (2 to 10) with 18 Nm  .

Tightening torque: 11 65 1AZ .

Release screws (1).

Tightening torque: 11 65 2AZ .

Remove heat shield (2) towards top.

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Tighten screws (1).

Tightening torque: 11 65 2AZ .

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Coat oil feed line (3) with engine oil and press in.

Insert and tighten screw (2).

Tightening torque: 11 42 4AZ .

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Coat oil return line (2) O-ring with engine oil and press in.

Install and tighten down screws (1).

Tightening torque: 11 42 7AZ .

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Install engine support arm.

Insert screws (2) and tighten.

Secure oxygen sensor (1) in bracket.

Tightening torque: 22 11 3AZ .

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Lower engine.

Insert screws (1) of both engine mounts.

To ensure play between engine mount and front axle support, lower the engine completely before tightening the screw connection (engine mount/front axle support).

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Tightening torque: 22 11 1AZ .

Assemble engine.

Clear fault memory in DME control unit.

Check air intake system for leaks.

Observe DME instructions.