Removing and installing/replacing exhaust turbocharger for cylinders 4-6 (S55 engine)

Special tools required: 

• 00 6 100

Necessary preliminary work: 

• Remove both catalytic converters. Refer to REMOVING AND INSTALLING/REPLACE CATALYTIC CONVERTER FOR CYLINDERS 1-3 and REMOVING AND INSTALLING/REPLACE CATALYTIC CONVERTER FOR CYLINDERS 4-6 .
• Drain COOLANT .
• 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).

Tightening torque 11 42 7AZ .

Release screw (2).

Tightening torque 11 42 6AZ .

Remove oil return line (3) in direction of arrow.

Installation note: 

Replace the gasket and O-ring.

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Release screws (1).

Release oil feed line (4).

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Release screw (1).

Tightening torque: 11 53 5AZ .

Pull off coolant return line (2).

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Disconnect coolant line (3) from auxiliary coolant pump for exhaust turbocharger.

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Release screw (1).

Pull off both coolant lines.

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Release screw (1).

Tightening torque 11 53 4AZ .

Unfasten screws (2).

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Release coolant delivery line and return line (3).

Installation note: 

Replace O-rings (3) of the feed line (1) and return line (2)

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Release screws (1).

Remove heat shield (2).

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Release all nuts in sequence (9 to 1).

Remove turbocharger towards bottom.

Graphic shows engine removed.

When replacing the exhaust turbocharger: 

Release screw (1).

Tightening torque 11 42 5AZ .

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

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Installation note: 

Replace O-rings (4) and gasket (3) of oil feed line (1) and oil return line (2).

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Release screws (1).

Tightening torque: 11 61 3AZ .

Remove pressure pipe (2).

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Green sealing ring (1) is at compressor output to the exhaust turbocharger.

Black sealing ring (2) at the charge air cooler.

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Installation: 

Replace seal (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 nut (1) with AF 11 to 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 9) with AF 10 to 12 Nm  .

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

Tighten nuts (2 to 9) to 18 Nm  .

Tightening torque: 11 65 1AZ .

Install heat shield (2).

Secure screws (1).

Tightening torque 11 65 2AZ .

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Press oil feed line (4) into oil hole.

Screw in the screw (1).

Tightening torque 11 42 4AZ .

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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.

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Assemble engine.

Clear fault memory in DME control unit.

Check air intake system for leaks.

Observe DME instructions.