Remove/install turbocharger

AR09.40-D-6020SF

Remove/install turbocharger

1.7.08

 

Remove/install

 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

Remove noise damper on turbocharger (1)

AR09.40-D-6920SF

2

Remove right holder (6) for air filter housing to firewall

AR09.10-D-1150-03SF

3

Unscrew bolts (2, 3) and remove support brace (4)



*BA09.40-N-1002-01Q

4

Disconnect electrical connector (5) at boost pressure positioner (Y77/1)

5

Remove catalytic converter (9) on turbocharger (1) and on cylinder head

 The catalytic converter (9) is not removed but simply pushed to the side.

AR49.10-D-5500SF

6

Remove bolts (7) and exhaust gas recirculation pipe (8)

 Installation: Replace seals (11) and bolts (7).



*BA14.20-N-1007-01H



*BA14.20-N-1008-01H

7

Remove bolts (13)

 Installation: Replace seals (15) and bolts (13).



*BA14.10-N-1003-01O

8

Remove bolts (14)



*BA09.40-N-1006-01Q

9

Remove bolts (12)

 Installation: Replace bolts (12).



*BA09.40-N-1003-01Q

10

Lift turbocharger (1) up and out

 To prevent damage caused by soilage, close off openings on turbocharger (1), left exhaust manifold (16), right exhaust manifold (17) and on oil supply connection fitting using suitable stop plugs.

 Collect escaping oil and remove soiling if necessary.

 Installation: Replace seal (18).



*001589019100



*129589009100

11

Remove exhaust collector pipe (10) from turbocharger (1)

 Only if installing new turbocharger (1) or in the case of leakage between exhaust collector pipe (10) and turbocharger (1).

AR09.40-S-6024-15SE



*BA09.40-N-1004-01Q

12

Install in the reverse order



Checking

13

Check engine oil level, correct if necessary



*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

14

Test run engine and check engine for leaks around turbocharger (1)

Number

Designation

Engine
642
in model
906

BA09.40-N-1002-01Q

Bolt, turbocharger to charge air manifold

Nm

10

BA09.40-N-1003-01Q

Fitted bolt, turbocharger to oil feed fitting

Stage 1

Nm

10

Stage 2

Nm

30

BA09.40-N-1004-01Q

Bolt, turbocharger to exhaust collector pipe

Stage 1

Nm

20

Stage 2

°

90

BA09.40-N-1006-01Q

Bolt, support brace to exhaust collector

Nm

30

Number

Designation

Engine
642
in model 906

BA14.10-N-1003-01O

Flange connection, exhaust manifold/front exhaust pipes to exhaust collector pipe

Stage 1

Nm

20

Stage 2

°

90

Number

Designation

Engine
642.992 in model 906

BA14.20-N-1007-01H

Exhaust gas recirculation pipe to charge air distribution line

Nm

13

BA14.20-N-1008-01H

Exhaust gas recirculation pipe to exhaust collector pipe

Stage 1

Nm

10

Stage 2

°

90

Number

Designation

Engine
642 in model 906 without particulate filter

Engine
642 in model 906 with particulate filter

BF18.00-N-1001-01L

Engine oil

Filling capacity
(oil and filter change)

Liters

12.5

12.5

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