Remove/install charge air ducts - AR09.41-P-8620MMB

ENGINES 157, 278 in MODEL 216, 221 

Fig 1: Identifying Charge Air Ducts Remove/Install Components

Courtesy of MERCEDES-BENZ USA

	Remove/install
	Risk of injury  caused by fingers being pinched or crushed  when removing, installing or aligning hoods, doors, trunk lids, liftgates or sliding roof	Keep body parts and limbs well clear of moving parts.	AS00.00-Z-0011-01A
1	Remove engine covers
2	Loosen clamp between upper charge air duct (1l, 1r) and air filter housing (4)	The boot between upper charge air duct (1l, 1r) and air filter housing remains on the air filter housing (4).
3	Loosen clamp between upper charge air duct (1l, 1r) and turbocharger	The boot between turbocharger and upper charge air duct (1l, 1r) remains on the upper air duct (1l, 1r).
4	Remove bolt for upper charge air duct (1l, 1r) on cylinder head cover		*BA09.40-P-1008-01R
5	Remove upper charge air duct (1l, 1r)	Plug openings.
			Figure
6	Remove air filter housing (4).
7	Remove engine oil cooling oil lines from oil filter housing and lay to the side outside the working area	Engine 157 Seal openings using stop plugs. Replace sealing rings and clean connection area of the oil lines.
			Figure
8	Loosen clamp between lower charge air duct (2l, 2r) and charge air cooler (6)	The boot between lower charge air duct (2l, 2r) and charge air cooler (6) remains on the charge air cooler (6).
9	Loosen clamp between lower charge air duct (2l, 2r) and turbocharger	The boot between lower charge air duct (2l, 2r) and turbocharger remains on the turbocharger.
10.1	Remove bolts for right lower charge air duct (2r) from cylinder head	When removing the right lower charge air duct (2r)
			*BA09.40-P-1008-01R
10.2	Remove bolts for left lower charge air duct (2l) from cylinder head and oil filter housing	When removing the left lower charge air duct (2r)
			*BA09.40-P-1008-01R
11	Remove lower charge air duct (2l, 2r)	Plug openings.
			Figure
	Checking
12	Check boot and rubber seal for cracks or damage and replace if necessary
13	Check clamps for damage and replace as necessary.
14	Install in the reverse order
	Checking
	Risk of accident  caused by vehicle starting off by itself when engine is running. Risk of injury  caused by contusions and burns during starting procedure or when working near the engine as it is running	Secure vehicle to prevent it from moving by itself. Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts.	AS00.00-Z-0005-01A
15	Carry out engine test run, checking the engine for proper operation and leaks

TURBOCHARGER

Number	Designation		Engine 157	Engine 278
BA09.40-P-1008-01R	Bolt, charge air manifold to front cover/oil filter housing/cylinder head/cylinder head cover	Nm	9	9

Fig 2: Identifying Set Of Stop Plugs (129 589 00 91 00)

Courtesy of MERCEDES-BENZ USA

Fig 3: Identifying Set Of Protective Covers (001 589 02 91 00)

Courtesy of MERCEDES-BENZ USA