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Turbocharger (B235R)

Turbocharger (B235R)

If the turbo must be replaced, carry out Before replacing the turbo .

To remove



1. Open the expansion tank cap to release system pressure.

2. Raise the car.

3. Drain the engine coolant by connecting a hose and opening the drain plug. Collect the coolant in a receptacle.

4. Remove the turbocharger stay.


5. Undo the bottom nut on the joint between the turbocharger and the front exhaust pipe.

6. Detach the coolant pipe from the turbocharger.

7. Undo the oil return pipe between the turbocharger and the cylinder block. Plug the hole in the block.

8. Detach the oil pipe from the oil filter adapter.

9. Detach the turbocharger outlet hose from the charge air cooler, plugging the turbocharger outlet with plug no. 83 94 595 or similar.

10. Lower the car to the floor.


11. Remove the connecting hose between the mass air flow sensor and the turbocharger inlet pipe.

12. Remove the bypass pipe with valve, keeping the O-ring from the connector to the turbocharger inlet pipe.

13. Remove the heat shield over the exhaust manifold.

14. Unplug the solenoid valve connector.

15. Remove the hoses to the solenoid valve, noting their locations.


16. Detach the crankcase ventilation pipe from the turbo inlet pipe and camshaft cover. Move the pipe to aside.

Keep track of the sealing washers.

17. Detach the EVAP purge hose from the T-connector on the solenoid valve.

18. Remove the engine lifting eye.

19. Remove the turbocharger inlet pipe.

20. Remove the 2 top nuts on the joint between the turbocharger and the front exhaust pipe.

Carefully move away the exhaust pipe and secure it with a strap or similar.

Important

The flexible bellow on the front section of the exhaust system must not be bent more than 5° from its neutral line. This means that if the front exhaust system is left hanging freely, it must not be bent more than by its own weight.

If the strain on the pipe is too great, its component parts will be permanently deformed. This can cause noise, leaks and eventually complete breakdown.


21. Detach the oil pipe from the turbocharger.

22. Detach both transverse coolant pipes from the cylinder head and pressure sensor mounting.

23. Detach the coolant hose from the turbocharger.


24. Remove the wastegate, 2 bolts and 1 clip.

25. Undo the nuts securing the turbocharger to the exhaust manifold.

26. Carefully lower the turbocharger.

Important

Do not bend the coolant pipe from the coolant pump.


27. Raise the car.

28. Carefully lift out the turbocharger.


To fit

Important

It is essential that there is oil in the turbocharger bearing housing when the engine is started, especially after a new turbocharger has been fitted.

Fill the turbocharger oil inlet with oil from an oil can. Spin the compressor wheel a number of times to lubricate the bearings.


Note

Apply a thin coat of Molykote 1000, part no. 30 20 971, or equivalent to the studs.

Make sure the sealing surfaces are clean before fitting


The wastegate must be removed from the turbocharger first if a new turbocharger is being fitted.



1. Fit a new gasket and carefully lift the turbocharger in place from below.

2. Lower the car to the floor.

3. Fit the nuts securing the turbocharger to the exhaust manifold.

Tightening torque: 24 Nm (18 lbf ft)

4. Fit the wastegate, 2 bolts and 1 clip.

5. Fit the coolant pipe to the turbocharger. Use new sealing washers.

Tightening torque: 25 Nm (18 lbf ft)

6. Fit the coolant pipe with new banjo bolt and new gaskets to the cylinder head and to the pressure sensor mounting.


Tightening torque: 25 Nm (18 lbf ft)

7. Fit the oil pipe to the turbocharger with new sealing washers.

Tightening torque: 20 Nm (15 lbf ft)

8. Release the front exhaust pipe and move it to its correct location. Tighten the 2 top nuts on the joint to the turbocharger.

Tightening torques:

Lock nuts: 24 Nm (18 lbf ft)

Important

The nuts must be tightened alternately when fitting the front exhaust pipe to the turbocharger so that the flange is not deformed. The exhaust pipe flange must not be in contact with the turbocharger flange.


9. Remove the plug in the turbocharger air intake. Check O-rings and apply acid-free Vaseline, part no. 30 06 665, or equivalent. Fit the turbocharger inlet pipe without tightening the V-clamp.

10. Connect the hoses to the solenoid valve, noting the markings on the hoses and connections, and fit the solenoid valve on the engine lifting eye.

11. Fit the engine lifting eye.

12. Tighten the turbocharger's intake pipe, V-clamp.

13. Connect the purge hose to the T-connection.

14. Fit the crankcase ventilation pipe to the turbocharger inlet pipe with new sealing washers.

Tightening torque: 24 Nm (18 lbf ft)

15. Fasten the crankcase ventilation pipe to the camshaft cover.


16. Fit the heat shield over the exhaust manifold.

17. Fit the bypass pipe and valve, using a new O-ring for the connection to the turbocharger inlet pipe.

Tightening torque 8 Nm (6 lbf ft)

Important

To reduce the risk of hoses mounted on the delivery side of the turbocharger coming loose due to low friction at high air pressures, the hoses and connecting pieces must be cleaned thoroughly before fitting. Use a rag dampened with 30 15 815 Cleaning agent to wipe clean inside the ends of the hoses. Clean also the connecting pieces. If hose clips are rusty or damaged, they must be replaced with new ones to maintain the correct clamping force.


18. Fit the connecting hose between the mass air flow sensor and the turbocharger inlet pipe.

19. Spray the solenoid valve connector with Kontakt 61, part no. 30 04 520, and plug it in.

20. Raise the car.


21. Remove the plug from the charge air cooler inlet pipe.

22. Connect the charge air cooler inlet pipe to the turbocharger.

Tightening torque: 8 Nm (6 lbf ft)

23. Fit the oil pipe from the turbocharger to the oil filter adapter with new copper washers.

Tightening torque: 25 Nm (18 lbf ft)

Important

It is extremely important to make sure that the connection is straight when tightened. Tighten the connection by hand initially to avoid misalignment and/or cross-threading. If necessary, slightly loosen the oil pipe from the turbocharger.


24. Fit the oil return pipe from the turbocharger to the cylinder block.

25. Fit the coolant pipe on the turbocharger with new sealing washers.

Tightening torque: 25 Nm (18 lbf ft)

26. Fit the bottom nut on the joint between the turbocharger and the front exhaust pipe.

Tightening torques:

Lock nuts: 24 Nm (18 lbf ft)

27. Fit the turbocharger stay.

Tightening torque: 24 Nm (18 lbf ft)

28. Check that the cooling system's drain plug is closed.

Lower the car to the floor.

29. Fill up with coolant. For the correct mixture, see Cooling system .

Close the filler cap.

30. Bleed the system; see Coolant (B235R) .

31. Raise the car to check for any oil or coolant leaks.

32. Lower the car and top up the oil and/or coolant as necessary.