Remove/install turbocharger

AR09.40-D-6020SD

Remove/install turbocharger

16.6.10



Removing

 Danger!

Risk of injury to skin and eyes caused by handling hot or glowing objects.

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

AS00.00-Z-0002-01A

1

Disconnect battery ground line

AR54.10-D-0003SD

2

Remove oil feed line

AR09.40-D-6022SD

3.1

Disconnect electrical connector (5)

Engine 646.984/985 without pneumatic boost pressure control

3.2

Detach vacuum line

Engine 646.984/985 with pneumatic boost pressure control

4

Take off clamp (1)

5

Remove intake air hose downstream of air filter (6)

AR09.10-D-8030-01SD

6

Lift/jack up vehicle

AR00.60-D-1000H

7.1

Detach charge air muffler (3) at turbocharger (4)

Engine 646.984/985

AR09.40-D-6920SD

7.2

Remove charge air hose on turbocharger (4)

Engine 646.989/990

8

Unscrew bolt (7)

9

Remove oil return flow line (8)

AR09.40-D-6021SD

10

Lower vehicle

11

Detach turbocharger (4) from exhaust manifold and remove

 Do not lift turbocharger (4) at control rod; otherwise, there is a risk of damaging turbocharger (4).

 The turbocharger (4) is fastened at the exhaust manifold with three bolts.



Install

12

Clean sealing surfaces and replace gasket

13

Replace sealing ring on the catalytic converter (2)

 Replace sealing ring if necessary.

14

Attach turbocharger (4) at exhaust manifold

 Use new bolts.



*BA09.40-N-1001-01O

15

Tighten down turbocharger (4) with clamp (1) on catalytic converter (2)



*BA14.40-N-1001-02D

16

Install oil feed line

AR09.40-D-6022SD

17

Lift/jack up vehicle

AR00.60-D-1000H

18

Tighten screw (7)



*BA09.40-N-1007-01O

19

Install oil return line (8)

AR09.40-D-6021SD

20.1

Mount charge air muffler (3) at turbocharger (4)

Engine 646.984/985

AR09.40-D-6920SD

 Inspect seal, replace if necessary.

20.2

Attach charge air hose on turbocharger (4)

Engine 646.989/990

 Check charge air hose; replace if necessary.



*BA09.41-N-1009-01M

21

Lower vehicle

22.1

Connect electrical connector (5)

Engine 646.984/985 without pneumatic boost pressure control

22.2

Put on vacuum line

Engine 646.984/985 with pneumatic boost pressure control

23

Attach intake air hose downstream of air filter (6)

AR09.10-D-8030-01SD

24

Connect ground cable to battery

AR54.10-D-0003SD

25

Check engine oil level, correct if necessary

 The engine oil level must not be above the maximum mark. This can lead to engine damage.

Engine oil, Specifications for Operating Fluids

*BF18.00-N-1001-01L

 Danger!

Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns during starting procedure or when working near the engine as it is running

Secure vehicle to prevent it from moving by itself.
Wear closed and snug-fitting work clothes.
Do not touch hot or rotating parts.

AS00.00-Z-0005-01A

26

Carry out engine test run and check engine for leaks around turbocharger (4)

Number

Designation

Engine
646.984/
985
in model 906

Engine
646.989/
990
in model 906

BA09.40-N-1001-01O

Flange connection, exhaust manifold to turbocharger

Nm

30

30

BA09.40-N-1007-01O

Bolt, support to turbocharger

Nm

30

30

Number

Designation

Engine
646
in model
906

BA09.41-N-1009-01M

Screw clamp, charge air hose to turbocharger

Tightening torque

Nm

4

Control torque (after a waiting time of approx. one hour)

Nm

4

Number

Designation

Engine
646

BA14.40-N-1001-02D

Pipe clamp connecting catalytic converter to turbocharger

Nm

15

Number

Designation

Engine
646 in model 906 without particulate filter

Engine
646 in model 906 with particulate filter

BF18.00-N-1001-01L

Engine oil

Filling capacity
(oil and filter change)

Liters

11

11

Specifications for Operating Fluids

Sheet

BB00.40-P-0228-03A

-

Sheet

BB00.40-P-0228-05A

-

Sheet

BB00.40-P-0228-51A

BB00.40-P-0228-51A

Sheet

BB00.40-P-0229-03A

-

Sheet

BB00.40-P-0229-05A

-

Sheet

BB00.40-P-0229-31A

BB00.40-P-0229-31A

Sheet

BB00.40-P-0229-51A

BB00.40-P-0229-51A