Remove/install aneroid capsule for wastegate valve - AR09.40-P-1002-03CD

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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 Dieselstrasse 34

Remove

Detach control line (1) from wastegate aneroid capsule (2).
Engine 651 in model 205, 222, 253
Remove locking plate at the control rod (3).

The locking plate is mounted over the nuts (4, 5) on the control rod (3).
Loosen nut (5).
Unscrew nut (4) on control rod (3).
Unscrew nuts (6) on wastegate aneroid capsule (2).
Remove wastegate aneroid capsule (2).

Fig 3: Control Rod, Wastegate Aneroid Capsule, Control Rod, Lever Mounting Bolt & Nuts
Courtesy of MERCEDES-BENZ USA

Install
Introduce wastegate aneroid capsule (2).
Lead control rod (3) through the hole in the lever mounting bolt (7).
Tighten nuts (6) .
Observe tightening torque.
Screw nut (5) in the direction of wastegate aneroid capsule (2).
in order to achieve the necessary clearance of the control rod (3).
Actuate wastegate aneroid capsule (2) up to the end stop with vacuum.
If the wastegate aneroid capsule (2) is new, actuate this a number of times with a vacuum using a manual vacuum pump and a vacuum tester of at least 700 mbar.
Press lever (7) up to the end stop in the direction of wastegate aneroid capsule (2) and hold.
Screw on nut (4) with zero clearance up to lever (7).
Mark nut (4) and screw by exactly two further revolutions onto the thread.
In order to achieve the necessary pretension.
Secure the control rod (3) against adjustment by locking the nut (5) against the 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 205, 222
The locking plate is mounted over the nuts (4, 5) on the control rod (3).
Place control line (1) on connection for wastegate aneroid capsule (2).