Remove/install charge air duct downstream of charge air cooler - AR09.50-P-8680H

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

ENGINES 285 in MODEL 240

Illustrated on model 240

Fig 1: Identifying Charge Air Duct Components

G07630337

Courtesy of MERCEDES-BENZ USA

	Remove/install
1	Remove engine trim panel	Engine 275.98	AR01.10-P-2405IM
1	Remove engine trim panel	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
2	Remove air filter housing	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 in the event of an accident.
3	Release hose clamps (1) on charge air hoses (2)		*BA09.41-P-1002-02B
4	Release hose clamps (3) on charge air duct (4)	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.
4	Release hose clamps (3) on charge air duct (4)		*BA09.41-P-1003-02B
5	Remove bolts (5)	Do not open the low temperature water circuit.
5	Remove bolts (5)		*BA09.41-P-1001-01G
6	Lever charge air cooler (6) out of charge air hoses (2)	Do not damage coolant hoses running to charge air coolers (6).
7	Take charge air cooler (6) out of charge air duct (4)
8	Remove charge air duct (4) from throttle valve actuator (M16/6) and take it out
9	Install in the reverse order

CHARGE AIR DUCT

Number	Designation		Engine 275, 285
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