ar0940d6020nb

Remove/install turbocharger

Typ ar · temat 09.40 · wersja 0101 · 2011-09-06

Dotyczy: ENGINES 647.981 in MODEL WD1, WD2, WD3, WD6, WD7, XD1, XD2, XD3, XD4, XD5, XD6, XD7, YD1, YD2, YD3, YD4, YD5, YD6, YD7 ENGINES 647.981 in MODELS 903.61 /66 /67, 904.61 /66 with CODE (ZU7) National version for Canada ENGINES 647.981 in MODELS 903.61 /66 /67, 904.61 /66 with CODE (ZU8) National version for USA ENGINES 647.981 in MODELS 903.61 /62 /66 /67, 904.61 /62 /66 with CODE (ZU9) National version for Mexico

Niedostępne w języku „pl”; wyświetlono w języku Angielski.

Umiejscowienie

Grupa funkcyjna 1 Silnik › 09 Zasysanie powietrza, doładowanie › 09.40 Turbosprężarka — Seria 647 (modele 981) · Seria 903 (modele 61*, 62*, 66*, 67*) · Seria 904 (modele 61*, 62*, 66*)

EinPAS 15 Silnik › 15.30 Ssanie powietrza/ doładowanie › 15.30.51 Turbosprężarka — Seria 647 (modele 981) · Seria 903 (modele 61*, 62*, 66*, 67*) · Seria 904 (modele 61*, 62*, 66*)

AR09.40-D-6020NB

Remove/install turbocharger

23.8.11

ENGINES 647.981 in MODEL WD1, WD2, WD3, WD6, WD7, XD1, XD2, XD3, XD4, XD5, XD6, XD7, YD1, YD2, YD3, YD4, YD5, YD6, YD7

ENGINES 647.981 in MODELS 903.61 /66 /67, 904.61 /66 with CODE (ZU7) National version for Canada

ENGINES 647.981 in MODELS 903.61 /66 /67, 904.61 /66 with CODE (ZU8) National version for USA

ENGINES 647.981 in MODELS 903.61 /62 /66 /67, 904.61 /62 /66 with CODE (ZU9) National version for Mexico

Remove/install turbocharger

D09.40-0031-09

1 Heat shield

2 Exhaust pipe

3 Exhaust clamp

4 Turbocharger

5 Charge pressure positioner

6 Electrical connector

7 Support brace

8 Bolt

17 Crankcase ventilation heating element

18 Air intake hose

19 Hose clamp

20 Crankcase ventilation hose

21 Charge air hose

22 Noise damper

23 Hose clamp

9 Bracket

10 Nuts

11 Bolts

12 Bolt

13 Oil feed line

14 Banjo bolt

15 Bolt

16 Electrical connector

Remove/install

Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

1

Open engine hood

2

Remove heat shield (1)

3

Remove exhaust clamp (3) from exhaust pipe (2) on turbocharger (4)

Installation: Check condition of exhaust clamp (3); replace if necessary.

4

Remove nuts (10) on bracket (9); push exhaust pipe (2) somewhat to the rear

5

Disconnect electrical connector (16) from crankcase ventilation heating element (17)

Installation: Ensure that electrical connector (16) is seated properly.

6

Detach hose for crankcase ventilation (20) from crankcase ventilation heating element (17)

Installation: Check condition of hose for crankcase ventilation (20); replace if necessary.

7

Detach air intake hose (18) at turbocharger (4)

Installation: Check condition of air intake hose (18) and hose clamp (19); replace if necessary.
Clean connection fitting from turbocharger (4) and air intake hose (18) otherwise the air intake hose (18) can unfasten from the turbocharger (4).

8

Remove charge air hose (21) on noise damper (22)

Installation: Check condition of charge air hose (21) and hose clamp (23); replace if necessary.
Clean connection fitting on noise damper (22) and charge air hose (21) otherwise the charge air hose (21) can detach from the noise damper (22).

9

Take off noise insulation (22) at turbocharger (4)

Installation: Replace sealing ring on noise damper (22).

10

Disconnect electrical connector (6) from boost pressure regulator (5)

Installation: Ensure that electrical connector (6) is seated properly.

11

Detach oil feed line (13) from cylinder head and turbocharger (4)

Installation: Replace sealing rings for banjo bolt (14) and the oil feed line (13).

*BA09.40-P-1004-01C

*BA09.40-P-1005-01C

12

Remove bolt (15) from support brace (7) on turbocharger (4)

Installation: Loosen bolt (8) in order to be able to install support brace (7) free of tension turbocharger (4).

*BA09.40-P-1006-01C

*BA09.40-P-1007-01C

13

Detach turbocharger (4) at exhaust manifold

Remove turbocharger (4) with oil return line. Collect escaping engine oil in a suitable container.

Installation: Replace sealing ring from oil return line below.

*BA09.40-P-1001-01C

14

Detach oil return flow line at turbocharger (4)

Only if replacing turbocharger (4).

Installation: Replace seal and sealing ring from oil return line flange on turbocharger (4).

Observe installation position of seal.

*BA09.40-P-1003-01C

15

Install in the reverse order

16

Inspect oil level in engine, adjust to correct level if necessary

Engine oil and filter change

AP18.00-D-0101A

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

17

Test run engine and check exhaust system for leaks

18

Allow engine to run until warm, then turn off engine and check for oil leaks

19

Check hose for crankcase ventilation (20), air intake hose (18) and charge air hose (21) for tight seating

Turbocharger

Number

Designation

Engine
647.981

BA09.40-P-1001-01C

Flange connection, exhaust manifold to turbocharger

Nm

30

BA09.40-P-1003-01C

Bolt, oil drain line to turbocharger

Nm

9

BA09.40-P-1004-01C

Oil feed line to turbocharger

Threaded fitting

Nm

20

Banjo bolt

Nm

18

BA09.40-P-1005-01C

Bolt, oil feed line to cylinder head

Nm

9

BA09.40-P-1006-01C

Bolt, support to turbocharger

Nm

30

BA09.40-P-1007-01C

Bolt, turbocharger support to crankcase

Nm

20

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