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

ENGINE 157, 278 in MODEL 217 

ENGINE 157, 278 in MODEL 222 

Shown on MODEL 222 

Fig 1: Charge Air Ducts Remove/Install Components - Shown On Model 222

Courtesy of MERCEDES-BENZ USA

Shown on engine 278 

Fig 2: Charge Air Ducts Remove/Install Components - Shown On Engine 278

Courtesy of MERCEDES-BENZ USA

	Risk of injury  caused by fingers being jammed or pinched when removing, installing or aligning hoods, doors, trunk lid/rear-end door or sliding roof.	No parts of the body or limbs should be within the operating area when the components are moving.	AS00.00-Z-0011-01A
	Remove/install
1	Remove respective engine covers (1, 2a, 2b)
2	Remove respective engine air intake duct (3a, 3b)
3	Detach engine oil cooling oil lines from oil filter housing and lay to the side outside the working area	When removing the left charge air line (10l, 20l)
4	Loosen clamp (11l or 11r) between the upper charge air line on the left (10l) or upper charge air line on the right (10r) and air filter housing	The boot between upper charge air line on the left (10l) or upper charge air line on the right (10r) and air filter housing remain on the air filter housing.
5	Loosen clamp (12l or 12r) between the upper charge air line on the left (10l) or upper charge air line on the right (10r) and ATL	The boot between the ATL and upper charge air line on the left (10l) or upper charge air line on the right (10r) remains on the upper charge air line on the left (10l) or upper charge air line on the right (10r).
6	Remove screw/bolt (13r or 13l) of the upper charge air line on the left (10l) or upper charge air line on the right (10r) on cylinder head cover	Bolt, charge air manifold to front cover/oil filter housing/cylinder head/cylinder head cover	*BA09.40-P-1008-01R
7	Remove upper charge air line on the left (10l) or upper charge air line on the right (10r)	Seal openings on charge air cooler and ATL. Set of protective caps	Figure
8	Remove air filter housing		AR09.10-P-1150LFB
9	Loosen clamp (21l or 21r) between the upper charge air line on the left (20l) or upper charge air line on the right (20r) and charge air cooler	The boot between lower charge air line on the left (20l) or lower charge air line on the right (20r) and charge air cooler remains on the charge air cooler.
10	Loosen clamp (22l or 22r) between the upper charge air line on the left (20l) or upper charge air line on the right (20r) and ATL	The boot between lower charge air line on the left (20l) or lower charge air line on the right (20r) and ATL remains on the ATL.
11	Remove screw/bolts (30r or 30l) of the lower charge air line on the left (20l) or lower charge air line on the right (20r) from the cylinder head cover
12	Remove screw/bolts (31r or 31l) of the lower charge air line on the left (20l) or lower charge air line on the right (20r) from the cylinder head or oil filter housing
13	Remove lower charge air line on the left (20l) or lower charge air line on the right (20r)	Seal openings on charge air cooler and ATL. Set of protective caps	Figure
	Check
14	Check all boots and rubber seals for cracks or damage and replace if necessary
15	Check all clamps for damage and replace as necessary
16	Install in the reverse order
	Risk of accident  from vehicle starting off by itself when engine running. Risk of injury  (bruises and burns) resulting from working on the engine while it is being started or when it is running.	Secure vehicle to prevent it from starting off by itself. Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts.	AS00.00-Z-0005-01A
17	Carry out an engine test run, checking the engine for proper operation and leaktightness

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

Courtesy of MERCEDES-BENZ USA