Remove/install air duct housing

AR09.20-P-0080OLI

Remove/install air duct housing

11.08.2020

Engine

654 in model 205, 253

with code M014 (Engine uprated)

Engine

656 in model 253

Modification notes

11.08.2020

Screw, exhaust gas turbocharger coolant lines

BA09.40-P-1007-02D

11.08.2020

Screw, exhaust gas turbocharger coolant lines

BA09.40-P-1017-02B

Shown on engine 654

1

Air duct housing

6

Connection holder

11

Boost pressure positioner

2

Charge air line

7

Bolts

12

Identification plate

3

Pressure line

8

Bolts

13

Rivet

4

Screw

9

Pressure line

14

Connection holder

5

Turbocharger

10

Coolant line

 Warning

Risk of injury to skin and eyes suffering scalding from contact with hot coolantspray. Risk of poisoning from swallowing coolant.

Do not open cooling system unless coolant temperature is below 90 °C. Open cap slowly and release the pressure. Do not pour coolant into beverage containers.
Wear protective gloves, protective clothing and safety glasses.

AS20.00-Z-0001-01A

 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

 Caution

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

 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

Topical note

Notes on coolant

AH20.00-N-2080-01A

Topical note

Information on preventing damage to electronic components due to electrostatic discharge

AH54.00-P-0001-01A

Topical note

Notes on threaded connections fastened using a tightening angle-based tightening process

AH00.00-P-0020-01A

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-P-5000-01A

 

Remove/install

1

Remove air intake line upstream of exhaust gas turbocharger (5).

AR09.40-P-0500OLI

 Installation: Do not install upper engine cover until after the leak test.

2

Open clamp and remove pressure line (3) from air duct housing (1).

 Installation: Replace clamp.

 Hose clamp pliers

*454589003700

3

Remove the charge air cooler and place to one side with lines attached.

Engine 656 in model 253

AR09.41-P-6817OIF

Engine 654 in model 205, 253
with code M014 (Engine uprated)

AR09.41-P-6817OLI

4

Remove charge air line (2) from chain case cover.

 Engine 656 in model 253Screw, charge air line to chain case cover/charge air pipe downstream of exhaust gas turbocharger

*BA09.41-P-1003-01BA

 Engine 654 in model 205, 253
with code M014 (Engine uprated)Screw, charge air line to chain case cover/charge air pipe downstream of exhaust gas turbocharger

*BA09.41-P-1004-01Y

5

Unscrew screw (4).

 Engine 656 in model 253Bolt, bracket to turbocharger/cylinder head

*BA09.40-P-1004-02D

 Engine 654 in model 205, 253
with code M014 (Engine uprated)Bolt, bracket to turbocharger/cylinder head

*BA09.40-P-1022-02B

6

Remove pressure line (9), seal openings with suitable stop plugs, and place low-pressure exhaust gas recirculation differential pressure sensor (B28/18) to one side with lines connected.


Do not crush or kink or subject lines to tension.
This would lead to damage to the lines and can impair their function.

 Union nut, pressure line to diesel particulate filter

*BA14.40-P-1001-01F

 Record plug

*129589009100

 Box wrench bit

*000589700300

7

Drain off coolant.

Engine 654 in model 205
with code M014 (Engine uprated)

AR20.00-P-1142OLI

Engine 654 in model 253
with code M014 (Engine uprated)
Engine 656 in model 253

AR20.00-P-1142OLG

8

Remove coolant line (10) from boost pressure regulator (11) and seal openings with suitable stop plugs.

 Installation: Check sealing ring, replace if necessary, and wet with lubricant.

Lubricant, rubber assembly 1 l

*BR00.45-Z-1010-06A

 Engine 656 in model 253Screw, exhaust gas turbocharger coolant lines

*BA09.40-P-1007-02D

 Engine 654 in model 205, 253
with code M014 (Engine uprated)Screw, exhaust gas turbocharger coolant lines

*BA09.40-P-1017-02B

 Record plug

*129589009100

 Assembly tool

*000589936300

9

Release and disconnect electrical connector from boost pressure regulator (11) and remove electrical wiring harness from boost pressure regulator (11).

10

Remove screws of boost pressure regulator (11) and place boost pressure regulator (11) to one side.

 Engine 654 in model 205, 253
with code M014 (Engine uprated)Screw, E-actuator to exhaust gas turbocharger

*BA09.40-P-1026-02B

 Engine 656 in model 253Screw, E-actuator to exhaust gas turbocharger

*BA09.40-P-1011-02D

11

Remove connection holder (6).

 Engine 656 in model 253Screw, exhaust gas turbocharger connection holder to engine charge air duct on exhaust gas turbocharger

*BA09.40-P-1008-02D

 Engine 654 in model 205, 253
with code M014 (Engine uprated)Screw, exhaust gas turbocharger connection holder to engine charge air duct on exhaust gas turbocharger

*BA09.40-P-1024-02B

12

Remove connection holder (14).

If installed.

 Engine 656 in model 253Screw, exhaust gas turbocharger connection holder to engine charge air duct on exhaust gas turbocharger

*BA09.40-P-1008-02D

 Engine 654 in model 205, 253
with code M014 (Engine uprated)Screw, exhaust gas turbocharger connection holder to engine charge air duct on exhaust gas turbocharger

*BA09.40-P-1024-02B

If air duct housing (1) is replaced:



The connection holder (14) is omitted.

13

Remove screws_(7).

 Engine 656 in model 253Screw, exhaust gas turbocharger to engine charge air duct on exhaust gas turbocharger

*BA09.40-P-1009-02D

 Engine 654 in model 205, 253
with code M014 (Engine uprated)Screw, exhaust gas turbocharger to engine charge air duct on exhaust gas turbocharger

*BA09.40-P-1025-02B

14

Remove screws (8).

 Engine 656 in model 253Screw, exhaust gas turbocharger coolant lines

*BA09.40-P-1007-02D

 Engine 654 in model 205, 253
with code M014 (Engine uprated)Screw, exhaust gas turbocharger coolant lines

*BA09.40-P-1017-02B

15

Remove charge air line (2) from air duct housing (1) and remove air duct housing (1).



BB00.40-P-0223-02A

 Installation: Install new sealing rings and wet with engine oil.

 Engine 656 in model 253Screw, charge air line to chain case cover/charge air pipe downstream of exhaust gas turbocharger

*BA09.41-P-1003-01BA

 Engine 654 in model 205, 253
with code M014 (Engine uprated)Screw, charge air line to chain case cover/charge air pipe downstream of exhaust gas turbocharger

*BA09.41-P-1004-01Y

 Assembly tool

*000589936300

16

Clean sealing surfaces with a lint-free rag.

17

Seal openings using suitable protective covers.

 Set of protective covers

*001589039100

 Set of protective caps

*001589029100

18

Drill rivet (13) and remove type plate (12).

When replacing the air duct housing (1).

19

Install in the reverse order.



Check

 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

20

Perform engine test run. While doing so, check engine for proper operation and leak tightness.

21

Install upper engine cover.



Engine 656 in model 253

AP01.10-P-2405-01L

Engine 654 in model 205, 253
with code M014 (Engine uprated)

AR01.10-P-2405OLI

 Turbocharger

Number

Designation

Engine 656

BA09.40-P-1004-02D

Bolt, bracket to turbocharger/cylinder head

M6

Nm

9

 Turbocharger

Number

Designation

Engine 656

BA09.40-P-1007-02D

Screw, exhaust gas turbocharger coolant lines

Nm

10

 Turbocharger

Number

Designation

Engine 656

BA09.40-P-1008-02D

Screw, exhaust gas turbocharger connection holder to engine charge air duct on exhaust gas turbocharger

M6

Nm

8

 Turbocharger

Number

Designation

Engine 656

BA09.40-P-1009-02D

Screw, exhaust gas turbocharger to engine charge air duct on exhaust gas turbocharger

M6

Nm

8

 Turbocharger

Number

Designation

Engine 656

BA09.40-P-1011-02D

Screw, E-actuator to exhaust gas turbocharger

Stage 1

Nm

8

Stage 2

°

20

 Turbocharger

Number

Designation

Engine 654 in model all
with code M014 (Engine uprated)

BA09.40-P-1017-02B

Screw, exhaust gas turbocharger coolant lines

Nm

10

 Turbocharger

Number

Designation

Engine 654 in model all
with code M014 (Engine uprated)

BA09.40-P-1022-02B

Bolt, bracket to turbocharger/cylinder head

M6

Nm

9

 Turbocharger

Number

Designation

Engine 654 in model all
with code M014 (Engine uprated)

BA09.40-P-1024-02B

Screw, exhaust gas turbocharger connection holder to engine charge air duct on exhaust gas turbocharger

M6

Nm

8

 Turbocharger

Number

Designation

Engine 654 in model all
with code M014 (Engine uprated)

BA09.40-P-1025-02B

Screw, exhaust gas turbocharger to engine charge air duct on exhaust gas turbocharger

M6

Nm

8

 Turbocharger

Number

Designation

Engine 654 in model all
with code M014 (Engine uprated)

BA09.40-P-1026-02B

Screw, E-actuator to exhaust gas turbocharger

Stage 1

Nm

8

Stage 2

°

20

 Charge air pipe/charge air cooling

Number

Designation

Engine 656

BA09.41-P-1003-01BA

Screw, charge air line to chain case cover/charge air pipe downstream of exhaust gas turbocharger

Nm

8

 Charge air pipe/charge air cooling

Number

Designation

Engine 654

BA09.41-P-1004-01Y

Screw, charge air line to chain case cover/charge air pipe downstream of exhaust gas turbocharger

Nm

8

 Diesel particulate filter

Number

Designation

Engine 654

Engine 656

BA14.40-P-1001-01F

Union nut, pressure line to diesel particulate filter

Nm

20

20

Repair materials

Number

Designation

Order number

BR00.45-Z-1010-06A

Lubricant, rubber assembly 1 l

A 000 989 03 67