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Exhaust manifold (B235R)

Exhaust manifold (B235R)

Dismantling

Warning

Be careful if the engine is hot. The coolant will be hot and there is also a danger of getting burnt on the exhaust manifold.




1. Open the expansion tank's filler cap to release system pressure.

2. Raise the car.

3. Drain the coolant by connecting a hose, opening the drain plug and collecting the coolant in a suitable receptacle.

4. Slacken the bolt securing the turbocharger mounting to the cylinder block.


5. Undo the upper bolt on the turbo's mounting.

6. Detach the coolant pipe from the turbocharger.

7. Detach the turbo's return hose to the sump.

8. Remove the turbo's oil pipe to the oil filter adapter, collect the oil in a receptacle.

9. Undo the lower nut on the joint between the turbocharger and the front exhaust pipe.

10. Lower the car to the floor.

11. Remove the bypass pipe with valve. Collect the O-ring at the connection to the turbo's intake pipe.


Bend the bypass pipe aside.

12. Remove the exhaust manifold's heat shield.

13. Unplug the solenoid valve's connector.

14. Remove the connecting hose between the mass air flow sensor and the turbo's intake pipe.

15. Detach the crankcase ventilation pipe secured to the turbo's intake pipe and the camshaft cover. Bent the pipe aside.


16. Detach the solenoid valve hoses, noting their positions.

17. Remove the engine's lifting eye.

18. Remove the turbo's intake pipe from the turbocharger, V-clamp.

19. Plug the turbo's inlet opening.

20. Undo the 2 upper nuts between the turbocharger and front exhaust pipe.

21. Carefully move the front exhaust pipe out of the way.

22. Remove the turbo's coolant return pipe from the cylinder head and pressure sensor mounting.

23. Remove the wastegate from the turbo, 2 bolts.

24. Undo the nuts securing the turbocharger to the exhaust manifold and slightly lower the turbocharger.

25. Relieve the multigroove V-belt of tension, using a flexible handle. Lock the belt tensioner with a 3 mm drill bit or the like.


26. Prise the belt off the power steering pump's pulley.

27. Remove the through bolts securing the pump to the bracket.


28. Swing the pump up and remove the lower bolt and the 2 upper bolts.

29. Carefully lift aside the power steering pump, complete with bracket, and secure it with a cable tie or the like.

30. Remove the exhaust manifold.



To fit


Important

Coat the studs and gasket sparingly with Molycote 1000, part no. 30 20 971, or the equivalent to prevent them from burning on solid.



1. Clean the contact surfaces and fit a new gasket on the exhaust manifold.

2. Lift the exhaust manifold into place.

3. Fit the washers, spacers and nuts.

Tightening torque: 25 Nm (18.4 lbf ft)

4. Fit the upper, long through bolt. The bolt head should face the air collector casing.


Fit the power steering pump in place.

5. Fit the lower bolt and the 2 upper bolts. Then fit the lower through bolt. Tighten the two through bolts.

Tightening torque: 24 Nm (17.7 lbf ft)

6. Use a flexible handle to relieve the belt tensioner of tension and remove the stop (drill bit or the like). Make sure that the belt is fitted correctly and carefully release the flexible handle.


7. Clean the contact surfaces and coat them sparingly with Molycote 1000, part no. 30 20 971, or the equivalent. Fit the turbocharger to the exhaust manifold and use a new gasket.


Tightening torques:

Locknuts: 24 Nm (17.7 lbf ft)

8. Position the front exhaust pipe's flange on the turbo and screw on the 2 upper nuts.

Important

It is extremely important to make sure that there is oil in the turbocharger's bearing housing when the engine is started.


9. Fit the turbo's wastegate in place, 2 bolts.

10. Fit the coolant return pipe to the turbocharger. Use new sealing washers.

Tightening torque: 25 Nm (18.4 lbf ft)

11. Tighten the coolant return pipe's connection to the cylinder head and secure the pipe to the pressure sensor bracket.

Tightening torque: 25 Nm (18.4 lbf ft)

12. Raise the car.


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

Tightening torque: 25 Nm (18.4 lbf ft)

14. Attach the turbo's return hose to the sump.

15. Connect the oil pipe from the turbo to the oil filter adapter. Use new sealing washers.

Tightening torque: 25 Nm (18.4 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 back off the oil pipe from the turbocharger.


16. Tighten the upper bolt and fit the bolt securing the turbo's mounting to the cylinder block.

Tightening torque: 24 Nm (17.7 lbf ft)

17. Fit the lower nut on the joint between the turbocharger and the front exhaust pipe.

18. Check that the tension of the multigroove V-belt is correct and that the coolant drain plug is properly tightened.

19. Lower the car to the floor.


20. Fit the intake pipe with lifting eye to the turbocharger. Adjust and tighten the intake pipe. Tighten the lifting eye.

21. Attach the solenoid valve's hoses, being careful to observe the markings on hose and connection.

22. Fit the solenoid valve.

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

23. Fit the crankcase ventilation pipe to the camshaft cover and to the turbo's intake pipe. Use new sealing washers.

Tightening torque: 24 Nm (17.7 lbf ft)

24. Fit the connecting hose between the mass air flow sensor and the turbo's intake pipe.


25. Fit the bypass pipe with valve. Fit a new O-ring lubricated with non-acidic vaseline, part no. 30 06 665, or the equivalent.

26. Fit the exhaust manifold's heat shield.

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

Close the filler cap.

28. Bleed the system as follows:

Note

The AC/ACC should be OFF.


• Fill the system to the MAX level, screw on the pressure cap, start the engine and warm it up at varying rpm until the radiator fan starts.

• Switch off the engine and top up as necessary to the MAX level.

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

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