Remove/install aneroid capsule for boost pressure control flap

AR09.40-D-1002-01WE

Remove/install aneroid capsule for boost pressure control flap

 Warning

Risk of injury. Skin or eye injuries may result when handling hot or glowing objects.

Wear protective gloves, protective clothing and safety glasses, if necessary.

AS00.00-Z-0002-01A

Engine

651 in model 900

Engine

651.955/957 in model 906

Modification notes

02.10.2019

Operation step "Attach/remove hand vacuum pump," added

Operation steps 9, 15

02.10.2019

Repair materials address changed to BR00.45-Z-1027-07A

Operation step 16

 Turbocharger

Number

Designation

Engine 651 in model 900

Engine 651 in model 906

BA09.40-N-1009-01R

Vacuum unit fastening nut on bracket/turbocharger

M6

Nm

9

9

Repair materials

Number

Designation

Order number

BR00.45-Z-1027-07A

"Yellow" locking paint

Lackfabrik Bäder GmbH & Co. KG
Dieselstrasse 34
73734 Esslingen
Germany
Tel.: +49 711 381607
Fax. +49 711 383092

1

Remove black-red vacuum hose (1) from the boost pressure control flap diaphragm capsule (2).

2

Loosen nut (5).

3

Remove nut (4) from the control rod (3).

4

Remove nuts (6) from the boost pressure control flap diaphragm capsule (2).

5

Remove boost pressure control flap aneroid capsule (2).

6

Bring boost pressure control flap aneroid capsule (2) into the installation position.

 To do this, insert insulating washer/sleeve between the boost pressure control flap diaphragm capsule (2) and the bracket and guide the control rod (3) through the hole in the mounting bolt of the lever (7).

7

Attach boost pressure control flap diaphragm capsule (2) with nuts (6) to the bracket   .

8

Turn nut (5) in the direction of the diaphragm capsule boost pressure control flap (2).

 in order to achieve the necessary clearance of the control rod (3).

9

 Attach hand vacuum pump to the boost pressure control flap diaphragm capsule (2).

10

Actuate boost pressure control flap diaphragm capsule (2) with  manual vacuum pump until control rod (3) is at end stop.

If a new boost pressure control flap diaphragm capsule (2) was installed,



actuate it multiple times with a vacuum of at least 700 mbar.

11

Press lever (7) to end stop in direction of boost pressure control flap diaphragm capsule (2) and hold.

12

Attach nut (4) to the lever (7) with zero clearance up to end stop.

13

Mark nut (4) and turn by exactly 3.5 revolutions on the thread in the direction of the lever (7).

 The required pretension is achieved in this way.

14

Secure control rod (3) with the nut (5) against the lever (7) and tighten the nut (5).

 While doing so, counterhold the nut (4).

15

 Remove hand vacuum pump from the boost pressure control flap diaphragm capsule (2).

16

Secure nuts (4, 5, 6) using temperature-resistant locking paint.

17

Attach black-red vacuum hose (1) to the boost pressure control flap diaphragm capsule (2).