11 65 020Damage on the exhaust turbocharger due to obstructed oil supply lines

Caution!

If there is damage on the exhaust turbocharger:

  • Complaint:

    Power loss, malfunction indicator lamp on

    Damage to the exhaust turbocharger.

    After damage to the exhaust turbochargers, the oil supply lines are often not replaced and the oil is not changed, this can lead to damage to the exhaust turbocharger again.

    Further, fault code entries in the preheating system or to the charging pressure controller (variable turbine geometry) are not considered.

    For N57X, additionally the following faults can be stored: 292200 Charging pressure controller (variable turbine geometry): Position sensor in charging pressure controller faulty or undervoltage 48F6 in charging pressure controller (variable turbine geometry)

    Attention: Subsequent damage is not covered by the warranty!

 

  • Cause

    The oil supply lines for the exhaust turbocharger are clogged or blocked by oil sludge/coking. Due to that, oil supply to the exhaust turbocharger may be inadequate and can cause damage to the exhaust turbocharger again.

    Malfunctions in the preheating system can lead to clogging of the diesel particulate filter and thus to problems with the charging pressure control or the charging pressure build-up. Consequence: Problems at cold start or the engine does not start due to a faulty preheating system. Power loss or overheating of the exhaust branch.

    If the new exhaust turbocharger is not filled with enough oil prior to installation, the shaft bearings can be damaged at the first starting operation itself.

 

  • Solution

    Proceed as follows in response to a customer complaint:

    If fault code entries are available for the preheating system, the preheating system must be repaired. Then delete the fault memory.

    Caution!

    If the engine does not heat up or only heats up very slowly because of a defective thermostat, this can result in premature or repeated damage to the exhaust turbocharger. Always check the coolant thermostat and thermostat for the EGR cooling if there is a complaint, and repair if applicable.

    Engine oil and filter exchange must be carried out on the engine absolutely, so as to guarantee operation of the changed exhaust turbocharger with fresh oil!

    Since the oil feed line as well as the oil return line may coke with increased mileage especially in the cable connection area of the exhaust turbocharger, the followings rules are applicable:

    Engines with one exhaust turbocharger:

    • Exhaust turbocharger exchange due to electrical fault on the exhaust turbocharger (vehicle mileage/km up to 100,000 km):
      • Check the oil feed line, oil return line and the associated banjo bolts for coking, replace if applicable.
      • If the oil return line is replaced, the connecting pipe on the crankcase must always be cleaned, as it is also subject to coking!
      • If a replacement is not necessary: If the exhaust turbocharger is offered only along with the oil return line and oil feed line in the Electronic Parts Catalogue (EPC), it can be removed from the order list again.
    • Exhaust turbocharger exchange due to electrical fault on the exhaust turbocharger (vehicle mileage/km starting at 100,000 km):
      • Replace the oil feed line, oil return line and the associated banjo bolts.
      • If the oil return line is replaced, the connecting pipe on the crankcase must always be cleaned, as it is also subject to coking!
    • Exchanging the exhaust turbocharger if there is mechanical damage on the exhaust turbocharger:
      • Always replace the oil feed line, oil return line and the associated banjo bolts.
      • If the oil return line is replaced, the connecting pipe on the crankcase must always be cleaned, as it is also subject to coking!

    Engines with several exhaust turbochargers:

    • Exchanging one or several exhaust turbochargers due to electrical faults on the exhaust turbocharger (vehicle mileage/km up to 100,000 km):
      • Check the oil feed lines, oil return lines and the associated banjo bolts of all exhaust turbochargers (including the intact exhaust turbocharger) for coking, replace if applicable.
      • If all the oil return lines are replaced, all the connecting pipes on the crankcase must always be cleaned, as they are also subject to coking!
      • If a replacement is not necessary: If the exhaust turbocharger is offered only along with the oil return line and oil feed line in the Electronic Parts Catalogue (EPC), it can be removed from the order list again.
    • Exchanging one or several exhaust turbochargers due to electrical faults on the exhaust turbocharger (vehicle mileage/km starting at 100,000 km):
      • Replace the oil feed lines, oil return lines and the associated banjo bolts of all exhaust turbochargers (including the intact exhaust turbocharger).
      • If all the oil return lines are replaced, all the connecting pipes on the crankcase must always be cleaned, as they are also subject to coking!
    • Exchanging one or several exhaust turbochargers if there is mechanical damage on the exhaust turbocharger:
      • Always replace the oil feed lines, oil return lines and the associated banjo bolts of all exhaust turbochargers (including the intact exhaust turbocharger).
      • If all the oil return lines are replaced, all the connecting pipes on the crankcase must always be cleaned, as they are also subject to coking!

     

    In case the diesel particulate filter is foul with oil, clean or replace it, if necessary.

    In order to exclude that the oil supply to the exhaust turbocharger is not impaired due to faulty crankcase ventilation, carry out a function check of the crankcase ventilation in this regard. The corresponding test module can be found in ISTA at:

    • Power train
    • Digital Diesel Electronics
    • Engine ventilation
    • Internal engine pressure

    When installing the exhaust turbocharger, the exhaust turbocharger itself needs to be filled to capacity with fresh engine oil through the oil intake hole before the oil feed line is mounted. Important: Never use liquid sealing compounds when connecting the engine oil pipe as they can block the oil ducts.

    After installing the exhaust turbocharger, start the engine and let it run at idle for 2 to 3 minutes before increasing the speed.

    If required, initiate a regeneration of the diesel particulate filter

    Important: For vehicles with N57x engines that have fault memory entries that are at the top, a successful diesel particulate filter regeneration must be carried out.

    Then delete the fault memory.


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