Remove/Install Air Duct Housing On Exhaust Gas Turbocharger - AR09.20-P-0001CD

ENGINE 651 in MODEL 166, 172, 204, 205, 212, 218, 222, 253

	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
	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
	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
	Notes on avoiding damage through contamination and foreign objects		AH00.00-P-5000-01A
	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 Do not install upper engine cover or cylinder head cover trim until after the leak test.	AR09.10-P-8130OLF
2	Remove air filter housing	Engine 651 in model 166, 172, 204, 212, 218	AR09.10-P-1150CD
2	Remove air filter housing	Engine 651 in model 222	AR09.10-P-1150OLF
3	Remove oil line on front bracket of air filter housing	M6x1	*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
6.1	Remove engine charge air duct upstream of charge air cooler	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)	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	Figure
11	Close openings with clean protective covers	Set of protective covers	Fig 2
12	Install in the reverse order
	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	M6x1	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

Fig 1: Identifying Set Of Protective Caps (001 589 02 91 00)

Courtesy of MERCEDES-BENZ USA

Fig 2: Identifying Set Of Protective Covers (001 589 01 91 00)

Courtesy of MERCEDES-BENZ USA

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