11 65 040 Remove and Install/Replace High Pressure Exhaust Turbocharger (Small Exhaust Turbocharger)

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 auxiliary materials.
Observe country-specific waste disposal regulations.





Necessary preliminary work:
^ Remove acoustic cover at rear
^ 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.

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).





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





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.

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








Feed out vacuum reservoir upwards and to side.





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

Tightening torque:11 00 2AZ.

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








Release screws (1).

Remove retaining plate (2).

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





Release screws on heat shield (1).

Tightening torque:11 00 2AZ.

Lift out heat shield.

Release screw (1).

Tightening torque:11 00 2AZ.





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





Slacken nut (1).

Pull line clip from stud bolt.

Tightening torque:11 00 2AZ.





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.





(E70 only)

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





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.





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.

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.





Release screws (1) on oil return pipe.

Tightening torque:11 00 2AZ.

Installation Note:
Replace beaded metal gasket.





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)





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