Remove/install turbocharger

AR09.40-D-6020SG

Remove/install turbocharger

05.02.2018

Engine

642.896/898/993 in model 906

Modification notes

04.03.2013

Screw/bolt, ATL to exhaust collector pipe

BA09.40-N-1004-01Q

14.02.2014

Fit bolt, ATL to oil supply connection fitting

BA09.40-N-1003-01Q

Show on model 906.133

1

Rail

7

Support brace

13

Left exhaust manifold

2

Bracket

8

Bolts

14

Bolts

3

Electrical connector

9

Rear EGR line

15

Bolts

4

Electrical connector

10

Exhaust collector pipe

16

Seal

5

Electrical line

11

Bolts

Y77/8

Boost pressure positioner

6

Turbocharger

12

Right exhaust manifold

Show on model 906.133

6

Turbocharger

10

Exhaust collector pipe

18

Seal

B16/11

Temperature sensor upstream of turbocharger

 Warning

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

 Caution

Risk of injury to skin and eyes due to handling of engine oil. Risk of poisoning caused by swallowing engine oil

Wear protective gloves, protective clothing and safety glasses.
Do not fill engine oil into beverage containers.

AS18.00-Z-0001-01A

 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

 

Remove/install

1

Remove trim panel on right cylinder head cover

AR01.20-D-5015SF

2

Remove right holder for air filter housing at firewall

AR09.10-D-1150-03SF

3

Remove noise damper on ATL (6)

AR09.40-D-6920SG

4.1

Unfasten rear EGR line (9) at exhaust collector pipe (10) and EGR bypass flap and press to the rear

Engine 642.896/898 in model 906

Engine 642.896/898 in model 906Exhaust collector pipe to EGR bypass flap

AR14.20-D-1060SD

4.2

Remove rear exhaust gas recirculation line (9)

Engine 642.993 in model 906

Engine 642.993 in model 906Exhaust collector pipe to EGR bypass flap

AR14.20-D-1060S

5.1

Remove catalytic converter

Engine 642.993 in model 906

Engine 642.993 in model 906

AR49.10-D-5500SF

5.2

Unclip bracket (2) on rail (1)

Engine 642.896/898 in model 906

6

Disconnect electrical connection (3) for temperature sensor upstream of ATL (B16/11)

Engine 642.896/898 in model 906

7

Expose electrical line (5) for temperature sensor upstream of ATL (B16/11)

Engine 642.896/898 in model 906

 Installation:
Ensure that the electrical line (5) is routed correctly. The heat protection hose must be located in the area of the ATL (6).
There may be some damage otherwise to the electrical line (5).

8

Disconnect electrical connection (4) at boost pressure positioner (Y77/8)

9

Remove screw/bolts (8) and take off support brace (7)

 Exhaust gas turbocharger support to charge air distributor

*BA09.40-N-1002-01Q

10

Remove screws (11)

 Installation: Replace screws (11).

 Screw/bolt, flange connection of exhaust manifold/front exhaust pipes to exhaust collector pipe

*BA14.10-N-1003-01O

 Set of flexible head wrenches

*001589810900

11

Remove bolts (14)

 Remove screw/bolts (14) from below.

 Installation: Replace screws (14).

 Bolt, support brace to exhaust collector

*BA09.40-N-1006-01Q

12

Remove screws (15)

 Installation: Replace screw/bolts (15).

 Fit bolt, turbocharger to oil supply connection fitting

*BA09.40-N-1003-01Q

13

Remove ATL (6) upwards

 Catch escaping engine oil and remove dirt if necessary.

 Installation: Replace seals (16, 18).

 Installation: Before inserting the ATL (6), fix the seals (16), each with 2 new screw/bolts (11), to the exhaust collector pipe (10).

 Set of protective covers

*001589019100

 Record plug

*129589009100

14

Seal off connections immediately using clean protective covers and stop plugs

 Set of protective covers

*001589019100

 Record plug

*129589009100

15

Remove temperature sensor upstream of ATL (B16/11) on ATL (6)

Engine 642.896/898 in model 906
When replacing the ATL (6).

 Installation:
While tightening ensure correct alignment of the electrical line (5). The heat protection hose must be located in the area of the ATL (6).
There may be some damage otherwise to the electrical line (5).

 Installation: Apply some hot lubrication paste to the thread of the temperature sensor upstream of ATL (B16/11).

 Exhaust temperature sensor to exhaust gas turbocharger

*BA07.04-N-1011-01G

Paste, hot lubrication 1 kg, DBL 6879.20

*BR00.45-Z-1005-06A

16

Replace seal between exhaust gas turbocharger (6) and exhaust gas collector pipe (10)

When replacing the ATL (6) and for a leaky seal.

AR09.40-S-6024-15SE

 Bolt, turbocharger to exhaust collector pipe

*BA09.40-N-1004-01Q



Clean

17

Clean sealing surfaces on right exhaust manifold (12), left exhaust manifold (13) and exhaust collector pipe (10)

18

Clean sealing surfaces on ATL (6)

Where exhaust gas turbocharger (6) is reused.

19

Install in the reverse order

20

Connect diagnostic system, read out fault memory and perform initialization of the boost pressure regulator (Y77/8)

After replacing the ATL (6).



AD00.00-D-2000-04SD

21

Check engine oil level; correct if necessary


The engine oil level must not lie above Max. and never below Min.
Engine damage may occur otherwise.

 Engine oil

*BF18.00-N-1001-01L

22

Perform an engine test run and check engine for leaks around turbocharger (6)

 Sensors, transmitters

Number

Designation

Engine 642

BA07.04-N-1011-01G

Exhaust temperature sensor to exhaust gas turbocharger

Nm

45

 Turbocharger

Number

Designation

Engine 642 in model 906

BA09.40-N-1002-01Q

Exhaust gas turbocharger support to charge air distributor

Nm

10

 Turbocharger

Number

Designation

Engine 642 in model 906

BA09.40-N-1003-01Q

Fit bolt, turbocharger to oil supply connection fitting

Stage 1

Nm

10

Stage 2

Nm

20

Stage 3

°

60

 Turbocharger

Number

Designation

Engine 642 in model 906

BA09.40-N-1004-01Q

Bolt, turbocharger to exhaust collector pipe

Stage 1

Nm

20

Stage 2

°

90

 Turbocharger

Number

Designation

Engine 642 in model 906

BA09.40-N-1006-01Q

Bolt, support brace to exhaust collector

Nm

30

 Exhaust manifold

Number

Designation

Engine 642 in model 906

BA14.10-N-1003-01O

Screw/bolt, flange connection of exhaust manifold/front exhaust pipes to exhaust collector pipe

Stage 1

Nm

20

Stage 2

°

90

 Filling capacities for engine lubrication system

Number

Designation

Engine 642 in model 906 except diesel particulate filter

Engine 642 in model 906 with diesel particulate filter

BF18.00-N-1001-01L

Engine oil

Filling capacity (oil and filter change)

Liter

12,5

12,5

Sheet

BB00.40-P-0228-03A

BB00.40-P-0228-51A

Sheet

BB00.40-P-0228-05A

BB00.40-P-0229-31A

Sheet

BB00.40-P-0228-51A

BB00.40-P-0229-51A

Sheet

BB00.40-P-0229-03A

BB00.40-P-0229-52A

Sheet

BB00.40-P-0229-05A

-

Sheet

BB00.40-P-0229-31A

-

Sheet

BB00.40-P-0229-51A

-

Sheet

BB00.40-P-0229-52A

-

Repair materials

Number

Designation

Order number

BR00.45-Z-1005-06A

Paste, hot lubrication 1 kg, DBL 6879.20

A 000 989 76 51