Remove/install turbocharger

AR09.40-D-6020R

Remove/install turbocharger

06.05.2016

Engine

646 in model 909

1

ATL

2

Hose

3

Splash panel

4

Electrical connection

5

Support brace

6

Pipe clamp

7

Screw/bolts

 Danger !

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

 

Remove/install

1

Remove air filter housing

AR09.10-D-1150R

2

Remove hose (2), check for damage and replace if necessary

3

Remove splash panel (3)

4

Release and disconnect electrical connection (4) on ATL (1)

5

Remove oil feed line

AR09.40-D-6022R

6

Remove support (5)

 Screw/bolt, support brace to turbocharger

*BA09.40-N-1007-01O

 Screw/bolt, turbocharger support brace to cylinder crankcase

*BA09.40-N-1005-01O

7

Remove oil return line

AR09.40-D-6021R

8

Detach charge air hose at ATL (1)

 Installation: Check screw clamp for damage and check function and replace as per findings.

 Charge air hose clamp to turbocharger

*BA09.41-N-1009-01M

9

Remove pipe clamp (6), check for damage and replace as per findings

 Installation: Replace sealing cone.

 Pipe clamp, catalytic converter to turbocharger

*BA14.40-N-1001-02D

10

Remove screws/bolts (7)

 Flange connection, exhaust manifold to turbocharger

*BA09.40-N-1001-01O

11

Remove ATL (1)

 Installation: Replace seal between exhaust manifold (1) and ATL.

12

Install in the reverse order

 Danger !

Risk of accident from vehicle starting off by itself when engine running. Risk of injury (bruises and burns) resulting from working on the engine while it is being started or when it is running.

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

AS00.00-Z-0005-01A

13

Perform an engine test run and check engine for leaktightness around ATL (1)

 Turbocharger

Number

Designation

Engine 646.7 in model 909

BA09.40-N-1001-01O

Flange connection, exhaust manifold to turbocharger

Nm

30

 Turbocharger

Number

Designation

Engine 646.7 in model 909

BA09.40-N-1005-01O

Screw/bolt, turbocharger support brace to cylinder crankcase

Nm

20

 Turbocharger

Number

Designation

Engine 646.7 in model 909

BA09.40-N-1007-01O

Screw/bolt, support brace to turbocharger

Nm

30

 Charge air pipe/charge air cooling

Number

Designation

Engine 646.7 in model 909

BA09.41-N-1009-01M

Charge air hose clamp to turbocharger

Tightening torque

Nm

4

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

Nm

4

 Exhaust aftertreatment

Number

Designation

Engine 646 in model 906, 909

BA14.40-N-1001-02D

Pipe clamp, catalytic converter to turbocharger

Nm

15