Dismantle, assemble turbocharger

AR09.40-I-6263A

Dismantle, assemble turbocharger

9.3.10

 

Remove/Install

1

Remove turbocharger

AR09.40-I-6020A

 

Disassemble/assemble

2

Mark position of compressor housing (1), compressor rear wall (8) and turbine housing (22) to bearing housing (16)

3

Open locking plates (24) and detach turbine housing (22) from the bearing housing (16)

 Carefully loosen turbine housing (22) if required using a plastic mallet from the bearing housing (16).
Do not tilt turbine housing (22).

 Installation: Replace locking plates and bolts (24).

Coat bolts with sealing compound



*BA09.40-N-1006-01G

*BR00.45-Z-1035-01A

4

Open locking plate (4) and remove compressor housing (1) from the compressor rear wall (8)

 Installation: install new sealing ring (2), locking plate (4) and bolts.

Coat bolts with sealing compound

 KKK turbocharger

*BA09.40-N-1007-01G

 Garret turbocharger

*BA09.40-N-1008-01G

*BR00.45-Z-1035-01A

5

Insert turbine wheel side of bearing housing (16) into the retainer and unscrew locknut (6)

 To loosen the locknut (6), use a T-head key to avoid warping the rotor shaft with the turbine wheel (21).

 Installation: replace locknut (6) and apply threadlocks.

 KKK turbocharger

*BA09.40-N-1011-01G

 Garret turbocharger

*BA09.40-N-1012-01G

*BR00.45-Z-1040-02A



Retainer for turbine wheel

WF58.50-N-0940-02A

6

Remove compressor wheel (7) from rotor shaft with turbine wheel (21)

7

Open locking plates (17) and detach compressor rear wall (8) from the bearing housing (16)

 Installation: install new sealing ring (9), locking plate (17) and bolts.

Coat bolts with sealing compound

Note the piston ring (10) .

 KKK turbocharger

*BA09.40-N-1009-01G

 Garret turbocharger

*BA09.40-N-1010-01G

*BR00.45-Z-1040-02A

8

Remove thrust ring (11) with fitted bearing (12) from rotor shaft with turbine wheel (21)

 Installation: ensure the thrust ring (11) and fitted bearing (12) are seated correctly in the retaining pins (13).

9

Press fitted bearing (12) out of thrust ring (11)

 Installation: Install new thrust ring (11).

10

Remove piston ring (10) from fitted bearing (12)

 Installation: Install new piston ring (10).

11

Remove bearing housing (16) from rotor shaft with turbine wheel (21)

12

Remove heat shield (19) from rotor shaft with turbine wheel (21)

13

Remove piston ring (20) on turbine side from rotor shaft with turbine wheel (21)

 The Garret turbocharger is equipped with a piston ring (20), on the KKK turbocharger there are two piston rings (20).

Installation : Install new piston ring (20).
With two piston rings (20), the piston ring end gaps must be positioned with a 180° offset.

14

Remove circlip (14) from bearing housing (16)

15

Remove both radial bearings (15) from the bearing housing (16)

 Installation: replace radial bearings (15) and lubricate with engine oil.



Check

16

Clean all parts of turbocharger, check for wear and damage, and replace if necessary.

 Replace worn or damaged parts.

17

Check concentricity deviation of the rotor shaft with turbine wheel (21)

AR09.40-I-6263-01A

KKK turbocharger

*BE09.40-N-1001-01C

Garret turbocharger

*BE09.40-N-1002-01C



*001589532100



*343589004000

18

Assemble in reverse order

19

Check unobstructed movement of the rotor shaft with turbine wheel (21)

20

Install in the reverse order

Number

Designation

Engine 384.906/
907

BE09.40-N-1001-01C

KKK turbocharger rotor shaft

Axial play

mm

0,16

Radial play

mm

0,46

Concentricity tolerance

mm

0,007

BE09.40-N-1002-01C

Garret turbocharger rotor shaft

Axial play

mm

0,10

Radial play

mm

0,76

Concentricity tolerance

mm

0,007

Number

Designation

Engine 384.906/
907

BA09.40-N-1006-01G

Bolt of turbine housing to bearing housing

Nm

20

BA09.40-N-1007-01G

Bolt of compressor housing to compressor rear wall on KKK turbocharger

Nm

10

BA09.40-N-1008-01G

Bolt of compressor housing to compressor rear wall on Garret turbocharger

Nm

20

BA09.40-N-1009-01G

Bolt of compressor housing to bearing housing on KKK turbocharger

Nm

10

BA09.40-N-1010-01G

Bolt of compressor housing to bearing housing on Garret turbocharger

Nm

20

BA09.40-N-1011-01G

Locknut of turbocharger wheel to rotor shaft on KKK turbocharger

1st stage

Nm

10

2nd stage

°

60

BA09.40-N-1012-01G

Locknut of turbocharger wheel to rotor shaft on Garret turbocharger

1st stage

Nm

20

2nd stage

°

90

Number

Designation

Order number

BR00.45-Z-1035-01A

Never Seeze NS 160 sealant

-

BR00.45-Z-1040-02A

Adhesive fastening, Loctite 648

A 003 989 32 71