Remove/install aneroid capsule for wastegate valve

AR09.40-S-1002-03E

Remove/install aneroid capsule for wastegate valve

 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

Model

447 with engine 651

Modification notes

02.10.2019

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

Operation steps 10, 16

02.10.2019

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

Operation step 17

 Turbocharger

Number

Designation

Engine 651 in model 447

BA09.40-N-1009-01R

Vacuum unit fastening nut on bracket/turbocharger

M6

Nm

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 vacuum hose (1) from wastegate aneroid capsule (2).

2

Remove safety clips (8).

3

Loosen nut (5).

4

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

5

Remove nuts (6) from the wastegate diaphragm capsule (2).

6

Remove wastegate aneroid capsule (2).

7

Bring wastegate aneroid capsule (2) into the installation position.

 To do this, guide the control rod (3) through the hole in the mounting bolt of the lever (7).

8

Attach wastegate diaphragm capsule (2) with nuts (6) to the bracket   .

9

Turn nut (5) in the direction of the wastegate diaphragm capsule (2).

10

 Attach hand vacuum pump to the wastegate diaphragm capsule (2).

11

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

If a new wastegate diaphragm capsule (2) was installed,



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

12

Press lever (7) to end stop in direction of wastegate diaphragm capsule (2) and hold.

13

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

14

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

 The necessary preload is achieved as a result.

15

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

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

16

 Remove hand vacuum pump of the wastegate diaphragm capsule (2).

17

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

18

Install safety clips (8).

19

Attach vacuum hose (1) to the wastegate diaphragm capsule (2).