Remove/Install Turbocharger - Ar09.40-D-6020TSV
Engine 642 in model 907
MODIFICATION NOTES
| 10.12.2020 | GB document reference added. | AR09.40-D-6024-15TSV | |
| 10.12.2020 | WSM link replaced with GB document reference. | Operation step 15 | |
| Risk of burn injuries,
suffocation and poisoning when working on the exhaust system and the components connected to it. Risk of suffocation and risk of poisoning caused by inhalation of gaseous and solid components of the exhaust. Risk of poisoning caused by skin contact with solid components of the exhaust. |
Wear protective clothing and safety glasses. Use the extraction system. Move people out of the hazard area. | AS49.00-Z-0001-01A | |
| 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 | |
| Risk of injury caused by scraping or cutting body parts on sharp vehicle parts | Always wear protective gloves when working on or near sharp and non-deburred vehicle parts. Deburr repair panels. |
AS00.00-Z-0017-01A | |
| 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 | |
| Notes on avoiding damage through contamination and foreign objects | AH00.00-P-5000-01A | ||
| Notes on threaded connections fastened using a tightening angle-based tightening process | AH00.00-P-0020-01A | ||
| Remove/install | |||
| 1 | Remove right holder for air filter housing at firewall. | AR09.10-D-1149TS | |
| 2 | Remove ventilation box. | AR83.10-D-0010TS | |
| 3 | Remove exhaust pipe downstream of the exhaust gas turbocharger (1). | AR49.10-D-5532TSV | |
| 4 | Remove rear exhaust gas recirculation line (2) from exhaust gas collector pipe (3), exhaust gas recirculation, and the brackets (4). | AR14.20-D-1061TSV | |
| 5 | Remove noise damper on exhaust gas turbocharger (1). | AR09.40-D-6920TSV | |
| 6 | Unclip bracket (5). | ||
| 7 | Disconnect electrical connector (6) for temperature sensor (7). | ||
| 8 | Disconnect electrical connector (8) for boost pressure actuator (9). | ||
| 9 | Remove bracket (10). | ||
| *BA09.40-N-1005-02TSV | |||
| 10 | Remove screws (11). | *BA14.10-N-1003-02TSV | |
| 11 | Remove screws (12). | *BA09.40-N-1006-02TSV | |
| 12 | Unscrew screws (13). | *BA09.40-N-1003-02TSV | |
| 13 | Remove exhaust gas turbocharger (1) upwards. | ||
| Fig 1 | |||
If exhaust gas turbocharger (1) is replaced, ↓ do not dispose of old seals from exhaust manifolds and from oil supply connection fitting yet. |
Fig 2 | ||
| 14 | Transfer temperature sensor (7). | If exhaust gas turbocharger (1) is replaced. | AR07.04-D-0244TSV |
| 15 | Replace seal between exhaust gas turbocharger (1) and exhaust gas collector pipe (3). | If exhaust gas turbocharger (1) is replaced. | |
| AR09.40-D-6024-15TSV | |||
| Clip: Replace seal between exhaust gas turbocharger and exhaust gas collector pipe | GB09.40-D-0000-04A | ||
| *BA09.40-N-1004-02TSV | |||
| Clean | |||
| 16 | Clean sealing surfaces on exhaust gas collector pipe (3), exhaust manifolds, and oil supply connection fitting. | The sealing surfaces can be damaged otherwise. |
|
| Assembly cleaner | *BR00.45-Z-1028-04A | ||
| 17 | Clean sealing surfaces on exhaust gas turbocharger (1). | If exhaust gas turbocharger (1) is reused. The sealing surfaces can be damaged otherwise. |
|
| Assembly cleaner | *BR00.45-Z-1028-04A | ||
| 18 | Install in the reverse order. |
| Number | Designation | Engine 642 in model 907 | ||
|---|---|---|---|---|
| BA09.40-N-1003-02TSV | Bolt, exhaust gas turbocharger to oil supply connection fitting | Stage 1 | Nm | 10 |
| Stage 2 | Nm | 20 | ||
| Stage 3 | ∠° | 60 | ||
| Number | Designation | Engine 642 in model 907 | ||
|---|---|---|---|---|
| BA09.40-N-1004-02TSV | Screw/bolt, turbocharger to exhaust collector pipe | Stage 1 | Nm | 20 |
| Stage 2 | ∠° | 90 | ||
| Number | Designation | Engine 642 in model 907 | |
|---|---|---|---|
| BA09.40-N-1005-02TSV | Bolt, bracket for exhaust gas turbocharger to charge-air distributor | Nm | 10 |
| Number | Designation | Engine 642 in model 907 | |
|---|---|---|---|
| BA09.40-N-1006-02TSV | Bolt, holder for exhaust gas collector pipe to exhaust gas collector pipe | Nm | 30 |
| Number | Designation | Engine 642 in model 907 | ||
|---|---|---|---|---|
| BA14.10-N-1003-02TSV | Bolt, exhaust manifold to exhaust gas collector pipe | Stage 1 | Nm | 20 |
| Stage 2 | ∠° | 90 | ||
REPAIR MATERIALS
| Number | Designation | Order number |
|---|---|---|
| BR00.45-Z-1028-04A | Assembly cleaner | A 000 986 56 01 |