Turbocharger

Turbocharger (B235R, B205L/R)





To remove

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

1. Open the cap on the expansion tank to release the pressure in the system.
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 brace supporting the turbocharger and the stay supporting the front exhaust pipe.
5. Undo the bottom nut on the joint between the turbocharger and the front exhaust pipe.
6. Place a receptacle under the car and disconnect 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. Place a receptacle under the car and disconnect the oil pipe from the oil filter adapter.
9. Disconnect the delivery pipe to the charge air cooler from the turbocharger. Plug the turbocharger outlet with 83 94 595 Plug, turbocharger hose or similar.
10. Lower the car.
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 on top of the exhaust manifold.
14. Unplug the solenoid valve's connector.
15. Remove the hoses to the solenoid valve, noting their locations.







16. Disconnect the crankcase ventilation pipe from the turbocharger intake pipe and the camshaft cover. Bend the pipe aside. Keep 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 upper nuts from the joint of the turbocharger and front exhaust pipe. Carefully move the exhaust pipe aside and secure it with a cable tie or similar.


IMPORTANT
The flexible section on the exhaust pipe must not be bent more than 5°. If this angle is exceeded, can be permanently deformed.


21. Remove the wastegate, 2 bolts and 1 clip.
22. Detach the oil pipe from the turbocharger.
23. Disconnect the cross-running coolant pipe from the cylinder head and pressure sensor bracket.
24. Remove the coolant pipe running from the coolant pump to the turbocharger.
25. Detach the coolant hose from the turbocharger.







26. Undo the nuts securing the turbocharger to the exhaust manifold.
27. Carefully lower the turbocharger.
28. Raise the car.
29. 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:
- Grease the studs with Molycote 1000, part no.30 20 971, or similar. Check that the sealing surfaces are clean prior to fitting.
- Use new gaskets.


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







2. Lower the car.
3. Fit the nuts securing the turbocharger to the exhaust manifold.
Tightening torque 24 Nm (18 lbf ft)
4. Fit the coolant pipe to the turbocharger. Use new seals.
Tightening torque 25 Nm (18 lbf ft)
5. Fit the coolant pipe with banjo bolt and new seals to the cylinder head and the pressure sensor bracket.
Tightening torque 25 Nm (18 lbf ft)







6. Fit the oil pipe to the turbocharger with new sealing washers.
Tightening torque 20 Nm (15 lbf ft)
7. Fit the coolant pipe running from the coolant pump to the turbo. Fit the wastegate, 2 bolts and 1 clip.
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 nut: 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 from the turbocharger air inlet. Inspect the O-ring and lubricate with acid-free petroleum jelly, part no.30 06 665, or similar. Fit the turbocharger intake pipe but do not fully tighten the V-clip.
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 V-clamp on the turbocharger inlet pipe.
13. Connect the purge hose to the T-connector.
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 on top of the exhaust manifold.
17. Fit the bypass pipe and valve. Use a new O-ring greased with petroleum jelly for the connection with the turbocharger intake pipe.
Tightening torque 8 Nm (6 lbf ft)
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 connect it.
20. Raise the car.
21. Remove the plug from the charge air cooler intake 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 essential that the connection is mounted straight when tightening. Tighten it by hand first to prevent it being threaded on crookedly. Loosen the oil pipe slightly on the turbocharger if necessary.


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 nut 24 Nm (18 lbf ft)
27. Fit the turbocharger stay.
Tightening torque 24 Nm (18 lbf ft)
28. Make sure the cooling system drain plug is closed.
Lower the car.
29. Fill with coolant.
Fit the cap.
30. Lift out the system as follows:


NOTE: AC/ACC should be OFF.


- Fill the system to MAX and fit the expansion tank cap. Start the engine. Run the engine unloaded at varying engine speeds until the radiator fan starts.
- Switch off the engine and top up as necessary to the MAX level.

31. Screw on the expansion tank cap.
32. Raise the car to check for oil or coolant leaks.
33. Lower the car and top up with coolant/oil as necessary.