Remove/install exhaust gas turbocharger together with exhaust manifold

AR09.40-B-6020-17EVI

Remove/install exhaust gas turbocharger together with exhaust manifold

Engine

936.9 in model 382.155/189

with code MS6 (Euro VI)

 Turbocharger

Number

Designation

ENGINE 936.9

BA09.40-B-1001-02EVI

Turbocharger nut in the exhaust manifold

Nm

50

 Turbocharger

Number

Designation

ENGINE 936.9

BA09.40-B-1006-02EVI

Screw of the thermal plate on turbocharger

Nm

25

 Turbocharger

Number

Designation

ENGINE 936.9

BA09.40-B-1007-02EVI

Oil pressure line on turbocharger connection

1st stage

Nm

10

2nd stage

0

45

 Turbocharger

Number

Designation

ENGINE 936.9

BA09.40-B-1009-02EVI

Screw of the oil return line on turbocharger

Nm

25

 Turbocharger

Number

Designation

ENGINE 936.9

BA09.40-B-1010-02EVI

Screw of the oil return line on crankcase

Nm

25

 Turbocharger

Number

Designation

ENGINE 936.9

BA09.40-B-1015-02EVI

Line connection clamp on turbocharger

Nm

5

 Turbocharger

Number

Designation

ENGINE 936.9

BA09.40-B-1018-02EVI

Rods on boost pressure/turbocharger positioner

Nm

6

 Turbocharger

Number

Designation

ENGINE 936.9

BA09.40-B-1019-02EVI

Turbocharger holder on crankcase/turbocharger by exhaust gas

Nm

25

 Turbocharger

Number

Designation

ENGINE 936.9

BA09.40-B-1025-02EVI

Elbow clamp with flange in turbocharger

Nm

11

 Turbocharger

Number

Designation

ENGINE 936.9

BA09.40-B-1026-02EVI

Charge air pipe holder on air intake pipe

Nm

20

 Turbocharger

Number

Designation

ENGINE 936.9

BA09.40-B-1027-02EVI

Charge air pipe clamp on turbocharger

Nm

6

 Turbocharger

Number

Designation

ENGINE 936.9

BA09.40-B-1028-02EVI

Cooling water pipe on pressure positioner

M6x12

Nm

10

 Turbocharger

Number

Designation

ENGINE 936.9

BA09.40-B-1029-02EVI

Screw of the upper part on lower part of the injection unit box

Nm

10

 Turbocharger

Number

Designation

ENGINE 936.9

BA09.40-B-1030-02EVI

Cooling water pipe at the injection unit/ crankcase

Nm

15

 Turbocharger

Number

Designation

ENGINE 936.9

BA09.40-B-1031-02EVI

Fitting nut of the fuel pipe at the injection unit

Nm

18

 Turbocharger

Number

Designation

ENGINE 936.9

BA09.40-B-1032-02EVI

Cooling water pipe on coolant/oil cooling module

Nm

30

 Turbocharger

Number

Designation

ENGINE 936.9

BA09.40-B-1034-02EVI

Oil pressure pipe on the crankcase

Nm

30

1

Remove the baffle plate (1).

2

Unscrew the screws (2), remove the bracket (3), and remove the V-clamp (4).

3

Disconnect the air bleed flexible hose (5) and remove the air intake pipe (6).

4

Disconnect the electric connector by the plug of the intake air temperature sensor (15B03).

5

Remove the V-clamp (7) and remove the supercharging air pipe (8).

6

Unscrew the hollow screw (9).

7

Remove the pipes of oil under pressure (10).

8

Disconnect the electric connector by the plug (arrow) of the electromagnetic valve.

9

Find out the electric wire of the electromagnetic valve.

10

Unscrew the screw (11) and remove the coolant pipe (12).

11

Unscrew the screws (13, 15, 16) and remove the bracket (14).

12

Remove the oil return pipe (17).

13

Unscrew the hollow screws (18) and remove the coolant pipes (19).

14

Remove the upper section of the box (20) of the injection unit.

15

Remove the fuel pipe (21) of the injection unit and then, remove the flanged tube (22).

 Collect the remaining fuel that flows out in a proper container and dispose it in an ecological way.

16

Disconnect the electric connector by the plug (arrow) of the lambda sensor (15B13).

17

Find out the electric wire of the lambda sensor (15B13).

18

Unscrew the screws (23, 24) until the bracket (25) can be moved sidewards.

19

Unscrew the screw (26) and remove the V-clamp (27).

20

Remove the flanged tube (22).

21

Unscrew the screws (28) and remove the coolant pipes (12, 29).

22

Remove the adjustment lever (30) of the turbocharger electromagnetic valve (10Y38).

23

Unscrew the screws (31).

24

Remove the exhaust gas supplying actuator (10Y67).

25

Unscrew the screws (32, 34) and remove the bracket (33, 35).

26

Remove the screws (36, 37) and remove exhaust gas recirculation pipe (38).

27

Unscrew the screws (39, 41, 42) and remove the bracket (40, 43).

28

Secure the exhaust gas turbocharger (46) with a proper lifting device to prevent it falls.

29

Remove the V-clamp (44) and unscrew the screws (45a, 45b).

30

Remove the exhaust gas turbocharger(46).

 It is necessary a helper to lift the exhaust gas turbocharger (46).

31

Fit all parts related to the exhaust gas turbocharger (46). 

 Only when the turbocharger (46) is replaced.

32

Carefully clean the sealing surface of the cylinder head.

33

Lubricate the thread of the screws (45b).

34

Fit the seals (47) and fasten them with the screws (45a).

 Install the screws (45a) and the seals (47).

 Screw the screws (45a) by approx. 3 turns.

35

Lubricate the thread of the screws (45b) and install the exhaust gas turbocharger (46).

36

Clean the sealing surface of the exhaust gas turbocharger (46).

37

Secure the exhaust gas turbocharger (46) to prevent it falls.

 It is necessary a helper to install the exhaust gas turbocharger (46).

38

Firmly tighten the screws (45a, 45b) and install the V-clamp (44).

39

Install the bracket (40, 43) and firmly tighten the screws (39, 41, 42).

 Install the screws (39, 41).

40

Install the exhaust gas recirculation pipe (38).

 Replace the gaskets.

41

Install the brackets (33, 35)

42

Install the turbocharger electromagnetic valve (10Y38).

43

Install the adjustment lever (30) of the turbocharger electromagnetic valve (10Y38).

44

Tighten the screws (31, 32, 34, 36, 37). 

45

Install the coolant pipes (12, 29). 

 Replace the ring gaskets.

46

Tighten the screws (28). 

47

Install the flanged tube (22) and screw the screws (26).

48

Install the V-clamp (27). 

49

Fasten the bracket (25) with the screws (23, 24).

50

Install the fuel pipe (21) in the injection unit. 

51

Install the upper section of the box (20) of the injection unit. 

52

Install the coolant pipes (19).

53

Tighten the hollow screws (18). 

 Replace the ring gaskets.

54

Connect the electric connection in the plug (arrow) of the lambda sensor (15B13).

55

Install the oil return pipe (17) and the bracket (14).

 Overall, the oil return pipe (17) must be replaced.
Not to do so can result in instability.

 Replace the gaskets

56

Firmly tighten the screws (13, 15, 16).   

57

Install the junction nut of the coolant pipe (12) and screw the screw (11). 

58

Connect the electric connector in the plug (arrow) of the turbocharger electromagnetic valve (10Y67).

59

Correctly fasten the electric cable of the turbocharger electromagnetic valve (10Y67).

60

Install the pipes of oil under pressure (10). 

 Overall, the pipes of oil under pressure (10) must be replaced, otherwise,
inadequate operation can occur.

61

Firmly tighten the hollow screw (9). 

 Replace the ring gaskets.

62

Connect the electric connector in the plug of the intake air temperature sensor (15B03).

63

Install the charge air pipe (8) and the V-clamp (7). 

64

Air intake pipe (6) and flexible bleed hose (5).

65

Install the bracket (3), tighten the screws (2), and install the V-clamp (4).   

66

Install the thermal protective plate (1). 