Remove/Install Charge Air Ducts - AR09.41-P-8620MLJ

Engine 157, 278 in model 166 

Engine 157, 278 in model 292 

Shown on engine 278 

Fig 1: Charge Air Ducts Components Location - Engine 278 In Model 166

Courtesy of MERCEDES-BENZ USA

	Remove/install
1	Remove upper engine covers
2	Detach engine oil cooling oil lines from oil filter housing and lay to the side outside the working area	Engine 157 in model 166, 292
		Seal openings with stop plugs. : Replace sealing rings and clean connection area of the oil lines.
		Record plug	Fig 3
3	Release clamp for upper charge air line on the left or for upper charge air line on the right (1r) and air filter housing (4)	The boot between upper charge air line on the left or upper charge air line on the right (1r) and air filter housing (4) remains on the air filter housing (4).
4	Release clamp for upper charge air line on the left (1l) or for upper charge air line on the right (1r) and ATL	The boot between the ATL and upper charge air line on the left (1l) or upper charge air line on the right (1r) remains on the upper charge air line on the left (1l) or upper charge air line on the right (1r).
5	Remove screw/bolt for upper charge air line or the left or upper charge air line on the right (1r) on cylinder head cover	Bolt, charge air manifold to front cover/oil filter housing/cylinder head/cylinder head cover	*BA09.40-P-1008-01R
6	Remove upper charge air line on the left o upper charge air line on the right (1r)	Seal off openings on charge air cooler (6) and ATL with protective cover.
		Set of protective caps	Fig 2
7	Remove air filter housing (4)
8	Release clamp between lower charge air line on the left (2l) or for lower charge air line on the right (2r) and charge air cooler (6)	The boot between lower charge air line on the left (2l) or lower charge air line on the right (2r) and charge air cooler (6) remains on the charge air cooler (6).
9	Release clamp for lower charge air line on the left (2l) or for lower charge air line on the right (2r) and ATL	The boot between lower charge air line on the left (2l) or lower charge air line on the right (2r) and ATL remains on the ATL.
10	Remove screw/bolts for right lower charge air line (2r) from cylinder head	When removing the right lower charge air line (2r)
		Bolt, charge air manifold to front cover/oil filter housing/cylinder head/cylinder head cover	*BA09.40-P-1008-01R
11	Remove screw/bolts for lower charge air duct on the left (2l) from cylinder head and oil filter housing	When removing left lower charge air line (2l)
		Bolt, charge air manifold to front cover/oil filter housing/cylinder head/cylinder head cover	*BA09.40-P-1008-01R
12	Remove lower charge air line on the left (2l) or lower charge air line on the right (2r)	Seal off openings on charge air cooler (6) and ATL with protective covers.
		Set of protective caps	Fig 2
13	Check boots and rubber seal for cracks or damage and replace if necessary
14	Check clamps for damage and replace as necessary
15	Install in the reverse order
	Check
	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
16	Carry out an engine test run, checking the engine for proper operation and leaktightness

Fig 2: Identifying Set Of Protective Caps (001 589 02 91 00)

Courtesy of MERCEDES-BENZ USA

Fig 3: Identifying Record Plug (129 589 00 91 00)

Courtesy of MERCEDES-BENZ USA