Remove/Install Diaphragm Capsule For WASTEGATE - Ar09.40-D-1002-04TSR

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.

Engine 651 in model 907

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

EXHAUST GAS TURBOCHARGER, OIL LINES

Number	Designation		Engine 651 in model 907
BA09.40-N-1010-02TSR	Nut, diaphragm capsule to diaphragm capsule holder	Nm	9

Fig 1: Hand Vacuum Pump (001 589 73 21 00)

REPAIR MATERIALS

Number	Designation	Order number
BR00.45-Z-1027-07A	"Yellow" locking paint	Lackfabrik Bader GmbH & Co. KG Dieselstrasse 34 73734 Esslingen Germany Tel.: +49 711 381607 Fax. +49 711 383092

Remove

Remove vacuum hose (1) from wastegate aneroid capsule (2).
Remove safety clips from the nuts (4, 5).
Loosen nut (5).
Remove nut (4) from the control rod (3).
Remove nuts (6) from the wastegate diaphragm capsule (2).
Remove wastegate aneroid capsule (2).
Install
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).
Attach wastegate diaphragm capsule (2) with nuts (6) to the bracket D .
Adjust
Turn nut (5) in the direction of the wastegate diaphragm capsule (2).
In order to achieve the necessary clearance of the control rod (3).
Attach hand vacuum pump to the wastegate diaphragm capsule (2).
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.
Press lever (7) to end stop in direction of wastegate diaphragm capsule (2) and hold.
Attach nut (4) to the lever (7) with zero clearance up to end stop.
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.
Secure control rod (3) with the nut (5) against the lever (7) and tighten the nut (5).
While doing so, counterhold the nut (4).
Remove hand vacuum pump of the wastegate diaphragm capsule (2).
Secure nuts (4, 5, 6) using temperature-resistant locking paint.
Attach safety clips of the nuts (4, 5).
Install vacuum hose (1) at boost pressure control flap diaphragm capsule (2).