Remove/install aneroid capsule for boost pressure control flap - AR09.40-P-1002-01CD

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ENGINE 651 in MODEL 166, 172, 204, 205, 207, 212, 218, 221, 222, 253

TURBOCHARGER

Number	Designation			Engine 651
BA09.40-P-1012-01P	Fastening nut on turbocharger vacuum unit	M6	Nm	9

Fig 1: Identifying Hand Vacuum Pump (001 589 73 21 00)

Courtesy of MERCEDES-BENZ USA

Fig 2: Identifying Vacuum Tester (201 589 13 21 00)

Courtesy of MERCEDES-BENZ USA

REPAIR MATERIALS

Number	Designation	Order number
BR00.45-Z-1027-07A	"Yellow" locking paint	Lackfabrik Bader GmbH & Co. KG

Remove

Detach control line (1) from boost pressure control flap aneroid capsule (2).
Engine 651 in model 222 Remove locking plate at the control rod (3).
Mount lock washer is mounted over the nuts (4, 5) on the control rod (3).

Fig 3: Control Line, Aneroid Capsule, Control Rod, Lever & Nuts
Courtesy of MERCEDES-BENZ USA
Loosen nut (5).
Unscrew nut (4) on control rod (3).
Unscrew nuts (6) on boost pressure control flap aneroid capsule (2).
Remove boost pressure control flap aneroid capsule (2).
Install
Introduce boost pressure control flap aneroid capsule (2).
Insert insulating sleeve on the holder side.
Tighten nuts (6) .
Screw nuts (5) in direction of diaphragm capsule of charge pressure control valve (2), to obtain the necessary clearance.
Attach hand-held vacuum pump and vacuum tester.
Actuate boost pressure control flap aneroid capsule (2) with vacuum all the way.
If the boost pressure control flap aneroid capsule (2) is new, actuate this a number of times with vacuum of at least 700 mbar.
Press lever (7) up to the end stop in the direction of boost pressure control flap aneroid capsule (2) and hold.
Screw down nut (4) without clearance against lever (7).
In order to achieve the necessary spring preload, mark nut (4) and screw onto thread by exactly 3.5 further revolutions.
Secure control rod (3), through locking a nut (5) against a nut (4).
Hold nut (4) firmly in the process using a counter wrench.
Secure nuts (4, 5, 6) using Yellow" locking paint.
Engine 651 in model 222
Mount lock washer over the nuts (4, 5) on the control rod (3).
Place control line (1) on connection for boost pressure control flap aneroid capsule (2).