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

Engine 256.9 in model 213, 238, 257, 290 

Shown without code M016 (uprated high-performance engine) 

Fig 1: Charge Air Distributor Component Location - Engine 256.9 In Model 257 (Shown Without Code M016)

Courtesy of MERCEDES-BENZ USA

	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  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	Release and disconnect pressure and temperature sensor electrical connector upstream of the throttle valve (B28/26) and place electric line to one side.	Do not install upper engine cover until after the leak test.	AR09.41-P-2011MSA
2	Drain coolant from low-temperature circuit.	Only install lower engine compartment paneling after leak test.	AR09.41-P-6834MSA
3	Remove charge air hose from additional compressor on the charge air line.	Engine 256.9 in model 213, 238, 257, 290 with code M016 (Uprated engine) Replace clamps.
		Clamp, charge air hose between charge air lines	*BA09.41-P-1017-01MRT
4	Remove bracket (5).	Screw, charge air line bracket to throttle valve actuator	*BA09.41-P-1005-01MRT
5	Remove front noise insulation from engine.
6	Release and disconnect intake camshaft Hall sensor electrical connector (B6/15).		AR15.12-P-2146MSA
7	Remove cable duct (1) from camshaft housing	Screw, engine wiring harness cable duct to camshaft housing	*BA15.18-P-1002-01MRT
8	Remove potential distributor (2) from camshaft housing.	Screw, engine wiring harness potential distributor to camshaft housing	*BA15.18-P-1003-01MRT
9	Remove bleed line from coolant hose (13) and seal openings with suitable stop plugs and place to one side.		AR20.20-P-7441-01RQ
		Record plug	Fig 3
10	Remove purging switchover valve (Y58/1).		AR47.30-P-8252MSA
11	Release and disconnect electrical connector (15) and place electric line to one side.
12	Remove coolant hoses (12, 13) from charge-air distributor (9) and seal openings with suitable protective covers.		AR20.20-P-7441-01RQ
		Set of protective caps	Fig 2
13	Remove oil filter element and seal opening with protective cover.
		Engine 256.9 in model 257.358	AP18.00-P-0101MRS
		Engine 256.9 in model 213, 238, 290 Engine 256.9 in model 257 (except 257.358)	AP18.00-P-0101MRT
		Set of protective caps	Fig 4
14	Remove 48 V wiring harness cable rails (8) from charge-air distributor (9) and from chain case cover and place electric line to one side.	M6X1	*BA00.10-P-1002-04A
15	Remove purge line (6) from purge line (7) and seal openings with protective covers.	Set of protective caps	Fig 2
16	Remove purge line (7) from charge-air distributor (9) and seal openings with protective covers and place to one side.	Set of protective caps	Fig 2
17	Remove partial load bleed line (4) from charge-air distributor (9) and seal openings with protective covers.	Set of protective caps	Fig 2
18	Release and disconnect pressure and temperature sensor electrical connector downstream of throttle valve (B28/27) and place electric line to one side.		AR09.41-P-2012MSA
19	Release and disconnect electrical connector a throttle valve actuator (M16/6).
20	Remove wiring harness (3) from charge-air distributor (9) and place to one side.
21	Remove the bolt (10).	Screw, coolant return line to charge air distributor	*BA09.41-P-1013-01MRT
22	Remove screw (11) from the support of the charge-air distributor.	Screw/bolt, support to charge air distributor	*BA09.41-P-1018-01MRT
23	Unscrew screw (14).	Screw/bolt, charge air line to chain case cover	*BA09.41-P-1002-01MRT
24	Remove screws of the charge-air distributor (9) in reverse order of the tightening procedure.	Tightening procedure for charge air distributor	AR09.41-P-8683-01MSA
		Screw/bolt, charge air distributor to cylinder head	*BA09.41-P-1001-01MRT
25	Remove charge-air distributor (9) and seal openings with clean rags.	Install new seals of the charge-air distributor (9) and throttle valve actuator (M16/6) on charge air pipe.
26	Remove throttle valve actuator (M16/6) from charger-air distributor (9).		AR07.51-P-1404MSA
		When replacing charge-air distributor (9).
27	Remove pressure and temperature sensor downstream of throttle valve (B28/27).		AR09.41-P-2012MSA
		When replacing charge-air distributor (9).
	Clean
28	Clean sealing surfaces of cylinder head and charge-air distributor (9).	Assembly cleaner	*BR00.45-Z-1028-04A
29	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
30	Carry out engine test run and check engine for proper operation and leak tightness.
31	Install upper engine cover.		AR01.10-P-2405MSA
32	Install lower engine compartment lining.	Engine 256.9 in model 213, 238	AR61.20-P-1105LWE
		Engine 256.9 in model 290	AR61.20-P-1105FRX
		Engine 256.9 in model 257	AR61.20-P-1105FR

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

Courtesy of MERCEDES-BENZ USA

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

Courtesy of MERCEDES-BENZ USA

Fig 4: Identifying Set Of Protective Caps (001 589 02 91 00)

Courtesy of MERCEDES-BENZ USA