Remove/install air duct housing on exhaust gas turbocharger

AR09.20-P-0001CD

Remove/install air duct housing on exhaust gas turbocharger

14.06.2017

Engine

651 in model 166, 172, 204, 205, 212, 218, 222, 253

1

Air duct housing

3

Screw

5

Sealing rings

2

Bolts

4

Sealing ring

6

Turbocharger

 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

 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

 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

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-P-5000-01A

Topical note

Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

 

Remove/install

1

Remove engine air intake duct downstream of air filter housing

Engine 651 in model 205, 253

AR09.10-P-8130OLD

Engine 651 in model 166, 172, 204, 212, 218

AR09.10-P-8130CD

Engine 651 in model 222

AR09.10-P-8130OLF

 Installation: Do not install upper engine cover or cylinder head cover trim until after the leak test.

2

Remove air filter housing

Engine 651 in model 166, 172, 204, 212, 218

AR09.10-P-1150CD

Engine 651 in model 222

AR09.10-P-1150OLF

3

Remove oil line on front bracket of air filter housing

 M61

*BA00.10-P-1002-04A

4

Remove front bracket of air filter housing on cylinder head

 Screw/bolt, air filter bracket to cylinder head

*BA09.10-P-1001-01K

5

Remove bracket through alternator

Engine 651 in model 172, 204, 212 (except 212.098), 218

Engine 651 in model 172, 204, 212 (except 212.098/298), 218

AR15.40-P-5032CD

6.1

Remove engine charge air duct upstream of charge air cooler

Engine 651 in model 166, 172, 204, 212, 218, 222

Engine 651 in model 222

AR09.41-P-8623OLF

Engine 651 in model 166, 172, 204, 212, 218

AR09.41-P-8619CD

6.2

Remove engine charge air duct upstream of charge air cooler on air duct housing (1) and place to one side

Engine 651 in model 205, 253

AR09.41-P-8623OLD

7

Remove screw (3)

 Screw/bolt, bracket to air duct housing/bracket

*BA09.41-P-1012-01N

8

Remove screw/bolts (2)

 Screw/bolt, air duct housing to exhaust gas turbocharger

*BA09.41-P-1011-01N

9

Remove air duct housing (1)

 Installation: Replace sealing rings (4, 5).

 Installation: Coat sealing ring (4) with antifriction paste.

Antifriction paste, rubber parts 2.5 kg, DBL 6867.00

*BR00.45-Z-1002-06A

10

Clean sealing surfaces at air duct housing (1) and at exhaust gas turbocharger (6) with lint-free cloth

11

Close openings with clean protective covers

 Set of protective caps

*001589029100

 Set of protective covers

*001589019100

12

Install in the reverse order

 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

13

Perform an engine test run and check engine for proper operation and leaktightness

14.1

Install upper engine cover

Engine 651 in model 166, 172, 205, 212, 218, 222, 253

14.2

Install cylinder head cover trim

Engine 651 in model 204

AR01.20-P-5014-02CD

 Metric screws/bolts and nuts as per MBN 10 105, 10 143

Number

Designation

8.8

10.9

BA00.10-P-1002-04A

M61

Nm

9

13

 Air filter

Number

Designation

Engine 651

BA09.10-P-1001-01K

Screw/bolt, air filter bracket to cylinder head

Nm

9

 Charge air pipe/charge air cooling

Number

Designation

Engine 651

BA09.41-P-1011-01N

Screw/bolt, air duct housing to exhaust gas turbocharger

Nm

9

 Charge air pipe/charge air cooling

Number

Designation

Engine 651

BA09.41-P-1012-01N

Screw/bolt, bracket to air duct housing/bracket

M6

Nm

9

Repair materials

Number

Designation

Order number

BR00.45-Z-1002-06A

Antifriction paste, rubber parts 2.5 kg, DBL 6867.00

A 000 989 01 60