Seal bypass flap of exhaust gas recirculation - AR14.20-P-0080CD

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ENGINE 651 in MODEL 166, 172, 204, 207, 212, 218, 221

Fig 1: Exhaust Gas Recirculation Seal Bypass Flap

Courtesy of MERCEDES-BENZ USA

	Remove/install
	Risk of injury to skin and eyes suffering scalding from contact with hot coolant spray. 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
1	Drain coolant at radiator	ENGINE 651 in MODEL 212 (except 212.098/298), 218, 221 Drain/pour in coolant	AR20.00-P-1142OMA
		Drain/pour in coolant ENGINE 651 in MODEL 172, 204, 207	AR20.00-P-1142CW
		Drain/pour in coolant ENGINE 651 in MODEL 166	AR20.00-P-1142GQ
2	Remove vacuum reservoir	Remove/install vacuum reservoir	AR07.09-P-0001CD
3	Loosen hose clamp (5) and detach coolant hose (6) from bypass valve	Check clamp (5) for damage; replace if necessary.
4	Detach vacuum hose (2) at vacuum unit (1)	Check vacuum hose for damage; replace if necessary.
5	Remove screw/bolts (3) and take off vacuum unit (1)	Do not disconnect the push rod on the vacuum unit (1) from the lever on the bypass flap (8). The vacuum unit (1) must be replaced completely otherwise with the bracket.
		Attachment of bolts, bypass valve vacuum unit holder to bypass valve	*BA14.20-P-1020-01K
6	Remove screw/bolts (4)	Bolt, cover to bypass valve housing	*BA14.20-P-1022-01K
7	Fasten vacuum unit (1) on again hand-tight using at least two screw/bolts (3) to the bypass flap (8)	This simplifies removal of the bypass flap (8) and protects the push rod on the vacuum unit (1) from getting damaged.
8	Remove bypass flap (8) with vacuum unit (1)
9	Removed molded seal (7)	When assembling the molded seal (7) do not use grease or oils. The molded seal (7) can be damaged otherwise. The molded seal (7) must be replaced. Immerse the molded seal (7) in water before assembly.
10	Install in the reverse order

EXHAUST GAS RECIRCULATION

Number	Designation			ENGINE 651
BA14.20-P-1022-01K	Bolt, cover to bypass valve housing	M6	Nm	12

EXHAUST GAS RECIRCULATION

Number	Designation			ENGINE 651
BA14.20-P-1020-01K	Attachment of bolts, bypass valve vacuum unit holder to bypass valve	M6	Nm	12