Remove/Install Charge Air Distributor - AR09.41-P-8683MFC

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Engine 260 in model 118, 177, 247

MODIFICATION NOTES

26.07.2021	Remove partial-load operation crankcase ventilation valve and place to one side.	Operation step 6.
26.07.2021	Remove bleed line of oil separator on charge-air distributor (18).	Operation step 13.

Courtesy of MERCEDES-BENZ USA

Courtesy of MERCEDES-BENZ USA

Fig 1: Charge Air Distributor Components Location - Model 118 In Engine 260

Courtesy of MERCEDES-BENZ USA

	Risk of injury. Skin or eye injuries may result when handling hot or glowing objects.	Wear protective gloves, protective clothing and safety glasses, if necessary.	AS00.00-Z-0002-01A
	Risk of injury to skin and eyes suffering scalding from contact with hot coolantspray. Risk of poisoning from swallowing coolant.	Do not open cooling system unless coolant temperature is below 90°C. Open cap slowly and release the overpressure. Do not pour coolant into beverage containers. Wear protective gloves, protective clothing and safety glasses.	AS20.00-Z-0001-01A
	Risk of injury to skin and eyes due to handling of engine oil. Risk of poisoning caused by swallowing engine oil	Wear protective gloves, protective clothing and safety glasses. Do not fill engine oil into beverage containers.	AS18.00-Z-0001-01A
	Risk of injury caused by scraping or cutting body parts on sharp vehicle parts	Always wear protective gloves when working on or near sharp and non-deburred vehicle parts. Deburr repair panels.	AS00.00-Z-0017-01A
Notice	Notes on avoiding damage through contamination and foreign objects		AH00.00-P-5000-01A
Notice	Information on preventing damage to electronic components due to electrostatic discharge		AH54.00-P-0001-01A
	Remove/install
1	Drain off coolant.		AR20.00-P-1142MFC
2	Remove purge valve.	: Do not install upper engine cover until after the leak test.	AR47.30-P-8252MFC
3.1	Remove upper part of charge air pipe from charge air cooler to charge-air distributor (18).	Engine 260 in model 118, 177, 247 except code M016 (Uprated engine) Do not kink the purge line (8). Otherwise damage will occur.	AR09.41-P-1331MFC
3.2	Remove charge air cooler.	Engine 260 in model 118, 177, 247 with code M016 (Uprated engine)	AR09.41-P-0105MFC
4	Remove purge lines (1, 8).
5	Seal openings with suitable stop plug.	Record plug	Fig 4
6	Remove partial-load operation crankcase ventilation valve and place to one side.	Engine 260 in model 118, 177, 247 except code 460 (Canada version) except code 494 (US version) except code 835 (South Korea version) except code 945 (China Stage 6 exhaust treatment)	AR01.20-P-0040MFC
		Engine 260 in model 118, 177, 247 with code 460 (Canada version) with code 494 (US version) with code 835 (South Korea version) with code 945 (China Stage 6 exhaust treatment)	AR01.20-P-0040MFD
7	Disconnect inerting line in engine compartment at separating point in area of firewall, place to one side and seal openings with suitable stop plugs.	Engine 260 in model 118, 177, 247 with code 2U8 (Alternative refrigerant) except code 460 (Canada version) except code 494 (US version) except code 835 (South Korea version) except code 945 (China Stage 6 exhaust treatment)	AR86.10-P-0119MFC
		Record plug	Fig 4
8	Disconnect engine wiring harness at cylinder head cover, place to one side and remove cable duct (2).		AR15.18-P-1000-04MFC
	Notes on safety-relevant components		AH00.00-Z-0019-01A
		Engine ground point	*BA00.19-P-1002-02E
9	Unclip electrical connector (6) at charge-air distributor (18).
10	Release, disconnect electrical connector (7) from throttle valve actuator (M16/6) and unclip below throttle valve actuator (M16/6).
11	Remove bolts (9) from connecting flange (10) at charge-air distributor (18).	Bolt, throttle valve actuator to charge air distributor	*BA30.20-P-1002-01C
12	Release catch hook (11) and remove connecting flange (10) with throttle valve actuator (M16/6) connected.	: Replace seal (15) and ensure seal (15) is correctly seated.
13	Remove bleed line of oil separator on charge-air distributor (18).
14	Remove screws at engine oil filler neck, unclip bleed line (12) at charge-air distributor (18) and place engine oil filler neck with connected bleed line (12) to one side.	Bolt, filler neck to cylinder head cover	*BA01.20-P-1003-03C
15	Cover openings with clean and lint-free rags.
16	Remove coolant line (13) at charge-air distributor (18), collect escaping coolant with rags and seal opening with suitable stop plugs.	Commercially available devices/tools Hose clamp pliers Set of plugs	Fig 3
17	Remove coolant line (14) at charge-air distributor (18) and seal opening with protective covers.		AR20.20-P-7441-01RQ
		Set of protective covers	Fig 2
18	Secure charge-air distributor (18) against falling down, release bolts (16) of charge-air distributor (18) in reverse order to tightening procedure and remove.	Tightening procedure for charge air manifold	AR09.41-P-1312-01MT
		Screw/bolt, charge air distributor to cylinder head	*BA09.20-P-1001-01U
19	Remove charge-air distributor (18).
20	Remove pressure and temperature sensor downstream of throttle valve (B28/27).	When replacing the charge-air distributor (18).
		Bolt, pressure sensor to charge air distributor	*BA09.20-P-1002-01U
21	Remove elastomer molded seals of charge-air distributor (18).	: Replace elastomer molded seals.
22	Clean sealing surfaces.	Loctite 7063 (400 ml) cleaning spray	*BR00.45-Z-1046-04A
23	Install in the reverse order.
24	Read out and delete fault memory.
			AD00.00-P-2000-06MFA
	Risk of burn injuries , suffocation and poisoning when working on the exhaust system and the components connected to it. Risk of suffocation and risk of poisoning caused by inhalation of gaseous and solid components of the exhaust. Risk of poisoning caused by skin contact with solid components of the exhaust.	Wear protective clothing and safety glasses. Use the extraction system. Move people out of the danger zone.	AS49.00-Z-0001-01A
	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
25	Perform engine test run. While doing so, check engine for proper operation and leak tightness.
26	Install upper engine cover.
			AP01.10-P-2405-01C

GROUND POINTS

Number	Designation				Model 118	Model 177
BA00.19-P-1002-02E	Engine ground point	W2/8	M5	Nm	9	9

GROUND POINTS

Number	Designation				Model 247
BA00.19-P-1002-02E	Engine ground point	W2/8	M5	Nm	9

CRANKCASE VENTILATION SYSTEM, CYLINDER HEAD COVER

Number	Designation		Engine 260
BA01.20-P-1003-03C	Bolt, filler neck to cylinder head cover	Nm	9

INTAKE MANIFOLD

Number	Designation		Engine 260
BA09.20-P-1001-01U	Screw/bolt, charge air distributor to cylinder head	Nm	14

INTAKE MANIFOLD

Number	Designation		Engine 260
BA09.20-P-1002-01U	Bolt, pressure sensor to charge air distributor	Nm	6

ELECTRONIC ACCELERATOR ACTUATOR

Number	Designation		Engine 260
BA30.20-P-1002-01C	Bolt, throttle valve actuator to charge air distributor	Nm	6

Fig 2: Identifying Set Of Protective Covers (001 589 06 91 00)

Courtesy of MERCEDES-BENZ USA

Fig 3: Identifying Set Of Plugs (199 589 00 98 00)

Courtesy of MERCEDES-BENZ USA

Fig 4: Identifying Record Plug (129 589 00 91 00)

Courtesy of MERCEDES-BENZ USA

REPAIR MATERIALS

Number	Designation	Order number
BR00.45-Z-1046-04A	Loctite 7063 (400 ml) cleaning spray	A 001 986 71 71 09