Remove/install air duct housing

AR09.20-S-0080EA

Remove/install air duct housing

06.03.2020

Engine

654.9 in model 447

1

Air duct housing

5

Screw

9.1

High-pressure turbocharger

2

Screw

6

Screw

9.2

Low-pressure turbocharger

3

Screw

7

Retaining plate

10

O-ring

4

Retaining plate

8

Bolts

1

Air duct housing

11

O-ring

13

Oil guide pipe

9.1

High-pressure turbocharger

12

O-ring

 Warning

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

 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

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-P-5000-01A

Topical note

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

AH00.00-P-0020-01A



Remove

1

Remove high-pressure exhaust gas turbocharger (9.1) and low-pressure exhaust gas turbocharger (9.2).

AR09.40-S-6020EA

2

Remove screw/bolt (2).

3

Remove screw (3) and remove retaining plate (4) from the air duct housing (1) and from the low-pressure exhaust gas turbocharger (9.2).

4

Remove screw (5).

5

Remove screw (6) and retaining plate (7) from the air duct housing (1) and remove from the high-pressure exhaust gas turbocharger (9.1).

6

Remove screws (8).

7

Remove air duct housing (1) from the high-pressure exhaust gas turbocharger (9.1) and from the low-pressure exhaust gas turbocharger (9.2).

8

Remove O-ring (12) from the high-pressure exhaust gas turbocharger (9.1).

 Assembly tool

*000589936300

9

Remove plain coupler (13) from the high-pressure exhaust gas turbocharger (9.1).



Clean

10

Clean sealing surfaces on the low-pressure exhaust gas turbocharger (9.2).

Assembly cleaner

*BR00.45-Z-1028-04A

11

Clean sealing surfaces on the high-pressure exhaust gas turbocharger (9.1).

Assembly cleaner

*BR00.45-Z-1028-04A

12

Seal high-pressure exhaust gas turbocharger (9.1) and low-pressure exhaust gas turbocharger (9.2) with protective covers.

 Set of protective caps

*001589029100

 Set of protective covers

*001589039100

13

Remove protective cover from air duct housing (1).

14

Remove O-ring (10) from air duct housing (1).

 Assembly tool

*000589936300

15

Remove O-ring (11) from air duct housing (1).

 Assembly tool

*000589936300



Clean

16

Clean sealing surfaces on the air duct housing (1).

Assembly cleaner

*BR00.45-Z-1028-04A

17

Seal air duct housing (1) with protective covers.

 Set of protective caps

*001589029100

 Set of protective covers

*001589039100



Install

18

Remove protective covers from air duct housing (1).

19

Attach new O-ring (11) to the air duct housing (1).

 Assembly tool

*000589936300

20

Attach new O-ring (10) to the air duct housing (1).

 Assembly tool

*000589936300

21

Remove protective covers from the high-pressure exhaust gas turbocharger (9.1).

22

Install new plain coupler (13) in the high-pressure exhaust gas turbocharger (9.1).

23

Attach new O-ring (12) to the high-pressure exhaust gas turbocharger (9.1).

 Assembly tool

*000589936300

24

Remove protective cover from the low-pressure exhaust gas turbocharger (9.2).

25

Attach air duct housing (1) to the high-pressure exhaust gas turbocharger (9.1) and to the low-pressure exhaust gas turbocharger (9.2).

26

Screw in new screws (8).

 Screw, air duct housing to high-pressure exhaust gas turbocharger

*BA09.40-N-1011-02EA

27

Position retaining plate (7) on the air duct housing (1) and on the high-pressure exhaust gas turbocharger (9.1).

28

Position new screw (6).

29

Screw in new screw (5).

 Screw, retaining plate to air duct housing and high-pressure exhaust gas turbocharger

*BA09.40-N-1012-02EA

30

Tighten screw (6).

 Screw, retaining plate to air duct housing and high-pressure exhaust gas turbocharger

*BA09.40-N-1012-02EA

31

Position retaining plate (4) on the air duct housing (1) and on the low-pressure exhaust gas turbocharger (9.2).

32

Position new screw (3).

33

Screw in new screw (2).

 Screw, retaining plate to air duct housing and low-pressure exhaust gas turbocharger

*BA09.40-N-1020-02EA

34

Tighten screw (3).

 Screw, retaining plate to air duct housing and low-pressure exhaust gas turbocharger

*BA09.40-N-1020-02EA

35

Install high-pressure exhaust gas turbocharger (9.1) and low-pressure exhaust gas turbocharger (9.2).

AR09.40-S-6020EA

 Turbocharger

Number

Designation

Engine 654.9 in model 447

BA09.40-N-1011-02EA

Screw, air duct housing to high-pressure exhaust gas turbocharger

Stage 1

Nm

8

Stage 2

°

20

 Turbocharger

Number

Designation

Engine 654.9 in model 447

BA09.40-N-1012-02EA

Screw, retaining plate to air duct housing and high-pressure exhaust gas turbocharger

Stage 1

Nm

8

Stage 2

°

30

 Turbocharger

Number

Designation

Engine 654.9 in model 447

BA09.40-N-1020-02EA

Screw, retaining plate to air duct housing and low-pressure exhaust gas turbocharger

Stage 1

Nm

8

Stage 2

°

30

Repair materials

Number

Designation

Order number

BR00.45-Z-1028-04A

Assembly cleaner

A 000 986 56 01