Tubocharger - Waste Gate, Updated Repair Kit

TO: OUR MERCEDES-BENZ PASSENGER CAR DEALERS

DATE: December 1986 REF.NO. 09/11


SUBJECT: REPAIR OR RENEWAL OF WASTE GATE MODEL 123 AND 126, ENGINE 617.95
A. GARRET TURBOCHARGER TA 0301
B. KKK TURBOCHARGER


A waste gate repair kit is now available for the Garrett turbocharger and a complete replacement waste gate for the KKK turbocharger.

FIGURE 1 - REMOVE SNAP RING:

A. Garrett Turbocharger TA 0301

1. Remove snap ring (arrow, Figure 1) using a screw driver. Remove cap with hose.

FIGURE 2 - STRAIGHTEN LOCKING TABS AND REMOVE COVER AND GASKET:

2. Straighten locking tabs (arrows, Figure 2). Unscrew nuts (M6) and remove cover and gasket.

FIGURE 3 - MEASURE DISTANCE WITH DEPTH GAUGE:

3. Unscrew lock nut while counter holding diaphragm. Measure distance "a" (Figure 3) with depth gauge and write down reading.
4. Counterhold valve with screw driver and unscrew diaphragm.

5. Remove valve and clean it.

6. Install new diaphragm and spring. Adjust to previously recorded distance "a" + 0.5 mm. Tighten lock nut while counterholding diaphragm.

FIGURE 1 - REMOVE SNAP RING:

7. Install cover with new gasket and new lock plates (arrows, Figure 1) . Tighten nuts and bend locking tabs.

FIGURE 4 - INSTALL SNAP RING:

8. Using a C-clamp, hold cap (item 8, Figure 4) in place to install snap ring (arrow) . Make sure that it is seated correctly.

FIGURE 5 - KKK TURBOCHARGER:

B. KKK Turbocharger

The waste gate (item 10, Figure 5) should be renewed with connecting hose (item 11), gasket and screws.
NOTE: Check valve seat, if damaged replace turbocharger. Following turbocharger installation, test the pressure. At full load, gear selector in position "L" and engine speed at 4000 rpm the pressure should be 0.7 to 0.9 bar.
Parts Information


Part Name Turbocharger Part Number


Waste gate repair kit Garrett
Waste gate KKK 617 096 00 80
000 090 00 75


Time Allowance

02-0906/35 Waste gate, repair (Garrett-Turbo)
36 (Turbocharger removed) 0.5 hrs.
37 56 66

02-0907/35 Waste gate, replace (KKK-Turbo) 0.3 hrs.
36 (Turbocharger removed)
37 56