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Turbo (B207R)

Turbo (B207R)

To remove

Warning

The turbocharger can be hot and great care must be observed.


Warning

The cooling system is under pressure. Hot coolant and steam can escape.

- Open the cap slowly to release the pressure.

- Carelessness can cause eye and burn injuries



1. Carefully undo the cap on the expansion tank to release the pressure.

2. Unplug the oxygen sensor and temperature sensor connectors and carefully lower the cables.


3. Remove the air cleaner casing and inlet hose to the turbo. Separate the casing first. Remove the hose to the crankcase ventilation and the SAI hose.


4. Remove the crankcase ventilation hose from the camshaft cover and the turbo inlet.

5. Remove the heat shield over the turbocharger.

6. Detach the solenoid valve hoses from the turbo.


7. Remove the pipe connection for the crankcase ventilation.

8. Remove the lock clip from the turbo control arm using a pair of flat nose pliers and a screwdriver. Remove the vacuum box from the turbo.

9. Remove the hose from the turbo bypass valve.

10. Remove the upper oxygen sensor. Move away the coolant reservoir for better access to the nuts.


11. Remove the nuts for the catalytic converter connection with the turbocharger.

Important

When removing the nuts of the catalytic converter, it is important to hold the removal tool vertically against the flange. The stud and nut can easily be broken off if they are subjected to a skew loading. Use 82 92 484 Removal tool, door hinge.


12. Raise the car.

13. Remove the front spoiler shield. See Spoiler shield, removal .

14. Place a receptacle under the car, connect a hose to the radiator and drain the coolant. Move the receptacle and drain the coolant pump.


15. Close the radiator cock and fit the drain plug. Seal the threads with Thread locking adhesive, Loctite 577 .

16. Lower the car.

17. Remove the turbo cooling pipe from the turbo and undo the water pipe mounting on the cylinder head.

Note

Grip the inner connection so it does not come loose from the turbo.



18. Remove the turbo oil pipe from the turbo.

19. Raise the car.

20. Remove the lower turbocharger pressure pipe.


21. Remove the front pipe from the catalytic converter. See Front pipe, To remove

22. Remove the heat shield over the steering gear.


23. Remove the heat shield over the catalytic converter and the mounting.

24. Remove the temperature sensor.


25. Remove the lower oxygen sensor.

26. Remove the catalytic converter fixing from the engine block.

27. Remove the catalytic converter.

28. Remove the turbo coolant pipe from the thermostat housing and turbo.


29. Remove the bolts on the turbo oil return pipe from the turbo, detach the pipe and O-ring from the connecting hole in the engine block.

Important

If the flexible part of the return oil pipe is bent, the resulting restriction may become permanent and cause damage to the turbocharger.


30. Remove the stay between the engine block and the turbo.

31. Release the turbo oil pressure pipe from the engine block and remove the pipe.


32. Remove and lift the turbo down.


To fit


1. Fit a new gasket.

2. Apply 30 20 971 Screw-thread paste to the turbo and exhaust manifold studs.

3. Lift up and fit the turbo.

Tightening torque 24 Nm (18 lbf ft)


4. Fit new sealing washers and screw in the bolt for the turbo oil delivery pipe on the engine block without tightening it.

5. Fit the turbo oil return pipe to the turbo with a new gasket and connect the pipe with a new O-ring, sparingly lubricated with Vaseline, non-acidic to the connecting hole in the engine block.

Tightening torque, oil return pipe to turbo 15 Nm (11 lbf ft)


6. Fit the coolant pipe between the turbo and the thermostat housing with new sealing washers.

Tightening torque 20 Nm (15 lbf ft).

7. Fit the strut between the turbo and engine block. Fit the bolts by hand, start by tightening the bolts in the turbo.

Tightening torque, bolt in turbo 32 Nm (24 lbf ft)

Tightening torque, M10 48 Nm (35 lbf ft)


8. Lower the car.

9. Fill with plenty of engine oil in the hole for the oil delivery connection on the turbo while turning the turbine wheel.

10. Fit the oil delivery pipe to the turbo and tighten the connection using new sealing washers. Grip the pipe so that it does not rotate.

Tightening torque 28 Nm (21 lbf ft)

11. Position and fit the coolant pipe to the turbo and tighten the pipe mounting on the cylinder head.


12. Connect the hose to the bypass valve.

13. Raise the car.

14. Tighten the oil delivery pipe connection on the engine block.

Tightening torque 28 Nm (21 lbf ft)

15. Lift up the catalytic converter, position its bracket to the studs on the engine block and position the catalytic converter to the turbocharger connection.


16. Insert the catalytic converter bracket bolts into the engine block and new nuts on the studs.

17. Lower the car.

18. Lubricate the turbocharger studs with 30 20 971 Screw-thread paste

19. Fit the catalytic converter with new nuts so that it rests evenly against the turbo.

Tightening torque 25 Nm (18 lbf ft).


20. Raise the car.

21. Tighten the catalytic converter nuts and bolts a last time.

Tightening torque, bolt 22 Nm (16 lbf ft).

Tightening torque nuts 25 Nm (18 lbf ft)


22. Lubricate the threads sparingly with 30 20 971 Screw-thread paste and fit the lower oxygen sensor.

Tightening torque 40 Nm (30 lbf ft).

Important

Make sure cables to the oxygen sensor are not twisted or damaged.


23. Lubricate the threads sparingly with 30 20 971 Screw-thread paste and fit the temperature sensor.

Tightening torque 45 Nm (33 lbf ft).

24. Lift up the oxygen sensor and temperature sensor cables.

Important

Make sure the cables are not exerted to chafing.


25. Fit the mounting and the heat shield onto the catalytic converter.


26. Fit the heat shield over the steering gear.

27. Clean the joint on the catalytic converter and the pipe connection to the front silencer. Mount the joint clamp and fit the front pipe with a new gasket, new nuts and rubber mountings. Lubricate the studs with 30 20 971 Screw-thread paste .

28. Move over the joint clamp so that the pipe ends are in the middle of the clamp.

29. Tighten the joint with the catalytic converter.

Tightening torque 25 Nm (18 lbf ft).


30. Tighten the joint clamp nuts.

Tightening torque 40 Nm (30 lbf ft).

31. Fit the turbocharger delivery pipe.


32. Fit the front spoiler shield. See Spoiler shield, To fit .

Tightening torque 25 Nm (18 lbf ft).

33. Lower the car.

34. Lubricate the threads sparingly with 30 20 971 Screw-thread paste and fit the upper oxygen sensor. Fit the coolant reservoir.

Tightening torque 40 Nm (30 lbf ft).


35. Plug in and secure the oxygen sensor and temperature sensor connectors.


36. Fit the vacuum unit to the turbo.


37. Position the control rod to the control arm and fit the lock clip.

38. Fit the pipe for the crankcase ventilation.

39. Fit the control valve hoses to the turbo.

40. Fit the turbocharger heat shield.


Important

To reduce the risk of hoses mounted on the delivery side of the turbocharger coming loose due to low friction at high air pressure, the hoses and connecting pieces must be cleaned thoroughly before fitting. Use a rag dampened with 93 160 907 Motip Dupli cleaning agent to wipe clean inside the ends of the hoses. Clean the connecting pieces as well. If hose clips are rusty or damaged, they must be replaced so the correct clamping force is maintained.


41. Fit the air cleaner casing and connect the inlet hose to the turbo. Fit the filter and the air cleaner casing cover.

42. Fit the crankcase ventilation hose to the camshaft cover and turbo as well as the hose from the solenoid valve.

43. Fill with coolant to approx. 20 mm above the mark on the expansion tank.

44. Check for coolant leaks.

45. Check the oil and coolant level and top up as necessary.