DIY turbo replacement '07 CX-7

[MFE]

We lost the turbo in my wife's CX-7 yesterday at 60,000 miles. The whole blue smoke no power thing as I pulled away from a stoplight. Thing is, a few miles later, the turbo surprisingly came back to life and got us home. I figure it was seized, and exhaust pressure got it unstuck for the ride home. Now sounds like a cross between a vacuum cleaner and a dying bathroom fan, and it obviously has to go.

Anyway, I'm a fairly experienced wrench, but I'm not a professional, and this car has required very little work, so I'm a complete virgin when it comes to its engine bay. I have some AllData info showing a pretty involved job. Anyone know of a DIY write-up for turbo work on these? Thanks in advance.

[Mandinca]

There's one for the ms 6 which shouldn't be far off. Apart from manifold bolts being rusted solid the other main issue is the oil drain bolts under the turbo. If you're FWD you can access them from underneath, if you're AWD the transfer case is in the way so you'll have to lie on the engine and undo the bolts by feel. Putting them back in while keeping the gasket in place is going to require some patience.
If you do it yourself get flex head ratchet wrenches, various extensions, a stubby ratchet, deep sockets and a can of PB Blaster to soak those manifold nuts overnight.


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[Ozynigma]

I am about to do this job voluntarily in the next month to upgrade from a K0422-582 to a MS3 K0422-882 turbo.

You will need a special tool to remove the first oxygen sensor which let's you remove the heat shield and then the upper down pipe from the turbo.

This is the O2 sensor tool I just ordered. http://bit.ly/1pZcrss

[Hargarbl]

Originally Posted by Ozynigma I am about to do this job voluntarily in the next month to upgrade from a K0422-582 to a MS3 K0422-882 turbo. You will need a special tool to remove the first oxygen sensor which let's you remove the heat shield and then the upper down pipe from the turbo. This is the O2 sensor tool I just ordered. http://bit.ly/1pZcrss

You can also rent the o2 sensor kit from advance or auto zone. I used it to remove my o2 when I did my dp.

[MFE]

Believe it or not, the dealership repaired it under warranty, even though it's long out of warranty (2007 with 60k on it). They stuck me for a new EGR valve but all in all I'll call it good.

[elessar78]

How much should I expect to pay at the dealership if my Turbo goes?

[Code Monkey]

A prolapsed rectum.

[Vansquish]

Originally Posted by MFE Believe it or not, the dealership repaired it under warranty, even though it's long out of warranty (2007 with 60k on it). They stuck me for a new EGR valve but all in all I'll call it good.

The EGR should probably have been a warranty item as well, as it's part of the emissions system that is warrantied beyond 60k.

[Ozynigma]

Originally Posted by elessar78 How much should I expect to pay at the dealership if my Turbo goes?

Why don't you ask them for a quote? Its a couple of days labour plus a few thousand for a genuine Mazda turbo.

There are better options like a BNR S1 as a replacement but if you can't do it yourself you will still have to pay a competent mechanic.

[elessar78]

Just out of curiosity I called and asked the dealership for a ball park to replace the turbocharger if it fails: $2500

What's the failure rate of the turbochargers? 25%, 50/50? 100% (after a certain amount of miles)?

[rudydecc]

There was a bad batch for the 2008.5s. I'll put it this way, the dealership sent my vin in to Mazda proper, and THEY called the dealership back stating a new turbo was in route. No pictures needed or questions asked (I had all new intake stuff and a dp on back done.) I don't know how far it reached besides the halfs, I imagine more of the 08s. So short answer, of it was an 08.5, failure is about 100%.

[elessar78]

I have a 2011, so less of a chance, if I'm reading you correctly.

[rudydecc]

Correct. 2010-11 was about the time Mazda started all their bs fixes for the 08 turbos.

That said, just watch it.

[stockms3]

Failure is 100%. Seals will eventually leak, nothing lasts forever.

[Ozynigma]

Originally Posted by elessar78 Just out of curiosity I called and asked the dealership for a ball park to replace the turbocharger if it fails: $2500 What's the failure rate of the turbochargers? 25%, 50/50? 100% (after a certain amount of miles)?

I am not sure if there are enough valid statistics available (unless Mazda has them) to give you a failure rate.

My 2007 built CX7 had the original model K04-581 turbo. It got to 130,000km with absolutely no issues at all. I then chose to replace it recently with the higher performance K04-882 turbo from a Gen2 Speed 3. The Gen 2 models of the 3 and CX7 had updated turbos the K04-582 and K04-882 (replacing the earlier K04-881). These have the improved seals.

The biggest cause of failures in CX7 turbos is lack of maintenance and in particular missing oil changes or extending the time/miles between services. Mazda recommend every 10,000km or every 6 months in Australia. I did let a few of my services go out to 12 months but still less than 10,000kms.

My opinion is that a well maintained CX7 motor should see 160,000km / 100,000 miles from a turbo. After this the failure rate is likely to increase. The turbo is a component under higher stresses and with higher wear rates than a lot of the other mechanical components on the car. So you would expect the rest of the engine to outlast a turbo.