Remove/install turbocharger

AR09.40-P-6020GD

22.5.97

ENGINE 668.940 /941 /942 in MODEL 168

P09.40-2009-09

Shown on engine up to 31.8.00

1 Air intake manifold

2 Hose clamp

3 Banjo screw

4 Sealing rings

5 Torx screw

6 Heat guard

7 Screw

8 Supporting strut

17 Noise insulation

18 Vacuum hose

110 Turbocharger

110/3 Oil feed line

110/4 Oil drain line

110/6 Charge air hose

110/10 Vacuum unit

120/1 Three way catalytic converter [TWC]

9 Screw

10 Pipe clamp

11 Exhaust manifold

12 Bolts

13 Torx screw

14 Hexagon socket bolt

15 Gasket

16 Hose clamp

Modification notes

14.3.02

Specification revised from 21 Nm to 30 Nm

Value in BA09.40-P-1004-01B for engine 668.940/941/942

*BA09.40-P-1004-01B

 	Remove, Install
1	Remove bottom part of noise encapsulation at front		AR94.30-P-5300GD
2	Detach air intake pipe (1) at turbocharger (110)	 Installation: Inspect condition of hose clamp (2), replace if necessary, install bolt head of hose clamp (2) at the front facing up.	AR09.10-P-8131GD
3	Remove induction module		AR09.20-P-1400GD
4	Take off catalytic converter	 Do not remove catalytic converter from engine compartment, but only place to the side.  Installation: Inspect pipe clamp (10), replace if necessary	AR49.10-P-5510GD
5	Detach vacuum hose (18) at vacuum unit (110/10)
6	Take off noise insulation (17) at turbocharger (110)	 Inspect condition of hose clamp (16) of charge air hose (110/6), replace if necessary.  Installation: Inspect condition of seal at noise insulation, replace if necessary
			*BA09.40-P-1005-01B
7	Detach oil feed line (110/3) at turbocharger (110)	 Installation: Replace sealing rings (4)
			*BA09.40-P-1003-01B
8	Detach oil drain line (110/4) at turbocharger (110)	 Collect oil which flows out in a suitable vessel.  Installation: Replace seal (15)
			*BA09.40-P-1002-01B
9	Detach support (8) and heat shield (6) at turbocharger (110)	 Carefully bend heat shield up in order to gain access to the bolts (12).  Installation: Slacken bolt (7) in order to be able to install support free of stress.
			*BA09.40-P-1004-01B
10	Detach turbocharger (110) at exhaust manifold (11)	 Installation: Clean sealing surfaces
			*BA09.40-P-1001-01B
11	Lift turbocharger (110) up and out
12	Install in the reverse order
13	Inspect engine oil level, adjust to correct level if necessary

 Turbocharger

Number	Designation		Engines 668.940 / 941/942


BA09.40-P-1001-01B	Bolt of turbocharger to exhaust manifold	Nm	21
BA09.40-P-1002-01B	Bolt of oil drain line to turbocharger	Nm	9
BA09.40-P-1003-01B	Banjo bolt of oil feed line to turbocharger	Nm	30
BA09.40-P-1004-01B	Bolt of support to turbocharger	Nm	30
BA09.40-P-1005-01B	Bolt of noise insulation to turbocharger	Nm	9

Commercially available tools

Number	Designation
WH58.30-Z-1001-06A	6 mm socket hexagon on flexible shaft for hose clamps with worm drive
WH58.30-Z-1002-06A	7 mm socket hexagon on flexible shaft for hose clamps with worm drive

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