Remove/install engine charge air duct upstream of charge air cooler - AR09.41-P-8623H

ENGINES 275 in MODEL 215, 216, 220, 221, 230 

ENGINES 285 in MODEL 240 

Fig 1: Identifying Engine Charge Air Duct Components

Courtesy of MERCEDES-BENZ USA

	Remove/install
1	Remove engine trim panel	Engine 275.98	AR01.10-P-2405IM
		Engine 275.95, 285	AR01.10-P-2405LA
2	Remove air filter housing	Model 215, 216, 220, 221, 230 without code (P99) Special Model "AMG Black Series"	AR09.10-P-1150LA
		Model 240	AR09.10-P-1150H
3	Release hose clamps (1) on charge air hoses (2)	Tighten hose clamps (1) using the prescribed torque so that charge air cooler (6) can separate from charge air ducts (7) in the event of an accident.
			*BA09.41-P-1002-02B
4	Loosen hose clamps (3) at charge air duct (4) downstream of charge air cooler (6)	Tighten hose clamps (3) using the prescribed torque so that charge air cooler (6) can separate from charge air ducts (4) in the event of an accident.
			*BA09.41-P-1003-02B
5	Remove bolts (5)	Do not open the low temperature water circuit.
			*BA09.41-P-1001-01G
6	Pull charge air cooler (6) and charge air hoses (2) out of charge air ducts (7)	Do not damage coolant hoses running to charge air coolers (6).
7	Remove fork (8)		*BA09.41-P-1001-02B
8	Remove charge air ducts (7) upstream of charge air coolers (6)
9	Install in the reverse order

CHARGE AIR DUCT

Number	Designation		Engine 275, 285
BA09.41-P-1001-02B	Bolt, charge air channel before charge air cooler to turbocharger	Nm	8
BA09.41-P-1002-02B	Hose clamp, charge air hose to engine charge air channel and to charge air cooler	Nm	3
BA09.41-P-1003-02B	Hose clamp, charge air channel as required charge air cooler to charge air cooler and to electronic accelerator actuator	Nm	3

CHARGE AIR PIPE/CHARGE AIR COOLING

Number	Designation		Engine 275, 285
BA09.41-P-1001-01G	Bolt, charge air cooler to cylinder head cover	Nm	8