ar0940p1008cd

Remove, install charge air bypass flap

Type ar · topic 09.40 · version 0101 · 2011-05-23

Applies to: ENGINES 651 in MODEL 204, 207, 212 only for two-stage charging

Where it sits

Function group 1 Engine › 09 Air intake, turbocharging › 09.40 Turbocharger — Series 204 · Series 207 · Series 212 · Series 651

EinPAS 15 Engine › 15.30 Air intake/charging › 15.30.31 Actuator motor/actuator/cylinder — Series 204 · Series 207 · Series 212 · Series 651

AR09.40-P-1008CD

Remove, install charge air bypass flap

13.5.11

ENGINES 651 in MODEL 204, 207, 212
only for two-stage charging

Remove, install charge air bypass flap

P09.40-2391-09

2 Air duct housing

8 Bolt

9 Bracket

13 Bolt

14 Bracket

10 Bolt

11 Bolt

12 Bracket

Remove, install charge air bypass flap

P09.40-2392-09

1 Bypass flap

2 Air duct housing

15 Bolt

16 Bolt

7 Aneroid capsule for turbocharger bypass flap

Remove, install charge air bypass flap

P09.40-2393-05

1 Bypass flap

1a Sealing ring

2 Air duct housing

2a Sealing ring

3 Lever

4 Control rod

5 Nut

6 Nut

7 Aneroid capsule for turbocharger bypass flap

Remove/install

Danger!

Risk of death caused by vehicle slipping or toppling off of the lifting platform.

Align vehicle between columns of vehicle lift and position four support plates at vehicle lift support points specified by vehicle manufacturer.

AS00.00-Z-0010-01A

1

Remove charge air hose upstream of charge air cooler

AR09.41-P-8619CD

2

Detach air filter housing

AR09.10-P-1150CD

3

Remove engine air intake duct downstream of air filter

AR09.10-P-8130CD

4

Remove impact plate in front of V-belt

5

Remove center bottom section of soundproofing

Model 204 except model 204.9

Model 204.9

AR61.20-P-1105CY

Model 207, 212

AR94.30-P-5300EW

6

Loosen bracket (9) on alternator and engine support, for this purpose unscrew bolts (8) from bottom

*BA09.40-P-1008-01P

7

Loosen bracket (9) on air duct housing (2), for this purpose unscrew bolt (10) from top

*BA09.40-P-1007-01P

8

Disconnect bracket (12) and bracket (14) from air duct housing (2); to this remove bolts (11) and (13) on air duct housing (2) and only loosen on turbocharger

*BA09.40-P-1017-01P

9

Remove vacuum hose from aneroid capsule for turbocharger bypass flap (7)

If installed.

10

Remove aneroid capsule for turbocharger bypass flap (7)

If installed.

AR09.40-P-1002-02CD

Installation: Adjust pretension on aneroid capsule for turbocharger bypass flap (7)

*BA09.40-P-1012-01P

11

Remove air duct housing (2), for this purpose unscrew bolts (15) and pull air duct housing (2) out of turbocharger

*BA09.40-P-1015-01P

Installation: Replace sealing ring (2a).

12

Remove bypass flap (1), for this purpose unscrew bolts (16) and pull bypass flap (1) out of turbocharger

*BA09.40-P-1016-01P

Installation: Replace sealing ring (1a).

13

Install in the reverse order

Turbocharger

Number

Designation

Engine 651

BA09.40-P-1007-01P

Bolt, turbocharger bracket to turbocharger bypass flap

M6

Nm

9

BA09.40-P-1008-01P

Bolt, turbocharger bracket to engine support/major assembly carrier

M8

Nm

20

BA09.40-P-1012-01P

Fastening nut on turbocharger vacuum unit

M6

Nm

9

BA09.40-P-1015-01P

Bolt, flanged pipe to bypass flap

Nm

9

BA09.40-P-1016-01P

Bolt, bypass flap to turbocharger

Nm

9

BA09.40-P-1017-01P

Bolt, turbocharger bracket to bypass flap/air duct housing

Nm

9

Referenced documents