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

Engine 256.9 in model 223

Fig 1: Charge Air Distributor Components Location - Engine 256.8 In Model 223

Courtesy of MERCEDES-BENZ USA

Courtesy of MERCEDES-BENZ USA

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 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	General information on vehicles with high-voltage on-board electrical system and/or lithium-ion battery and/or gaseous-fuel drive system as well as personal protective equipment		AH00.00-Z-0300-01A
Notice	Information on preventing damage to electronic components due to electrostatic discharge		AH54.00-P-0001-01A
Notice	Notes on avoiding damage through contamination and foreign objects		AH00.00-P-5000-01A
	Notes on safety-relevant components		AH00.00-Z-0019-01A
	Remove/install
1	Remove voltage of high-voltage on-board electrical system.	Engine 256.9 in model 223 with code ME10 (Hybrid vehicle (plug-in, PHEV))	AR47.70-P-1000SE
2	Drain coolant of low-temperature circuit.	: Only install lower engine compartment lining after leak test.	AR20.00-P-1144SB
3	Remove air filter housing.	: Do not install upper engine cover until after the leak test.	AR09.10-P-1150SB
4	Remove wide open throttle bleed line from oil separator.		AR01.20-P-0020SB
5	Remove rear noise insulation above the cylinder head cover.
6	Release and disconnect electrical connector at charge air pressure/temperature sensor (B159/1).
7	Disconnect and release electrical connector at charge air pressure/temperature sensor (B159/2).
8	Remove electric line (2) from charge-air distributor (1) and place to one side.	Dismantling tool	Fig 5
9	Remove coolant line from partition.		AR20.20-P-7441-01RQ
10	Remove screw (3).	Screw/bolt, charge air line to chain case cover	*BA09.41-P-1002-01MRT
11	Remove charge air line (4).	Clamp, charge air hose between charge air lines	*BA09.41-P-1017-01MRT
12	Remove electric line from bracket (5).	Dismantling tool	Fig 5
13	Remove bracket (5) from the throttle valve actuator (M16/5).	Screw, charge air line bracket to throttle valve actuator	*BA09.41-P-1005-01MRT
14	Remove charge air line (6) from the throttle valve actuator (M16/5).	: Replace sealing ring and moisten with lubricant. Lubricant, rubber assembly 1 L	*BR00.45-Z-1010-06A
		Assembly tool	Fig 2
15	Release and disconnect electrical connector at throttle valve actuator (M16/5).
16	Unscrew screw (8).	Screw, coolant return line to charge air distributor	*BA09.41-P-1013-01MRT
17	Remove coolant lines (9) from the charge-air distributor (1) and seal exposed openings with protective covers.		AR20.20-P-7441-01RQ
		Set of protective covers	Fig 3
18	Remove purge valve (Y58/20).		AR47.30-P-8252S
19	Release and disconnect electrical connector (10).
20	Remove electric lines (11) from the charge-air distributor (1) and place to one side.	Dismantling tool	Fig 5
21	Remove purge line (12) from purge line (13) and seal exposed openings with suitable stop plugs.	Record plug	Fig 4
22	Remove purge line (13) from the charge-air distributor (1), place it to one side and seal exposed openings with suitable stop plugs.	Record plug	Fig 4
23	Remove bleed line (14) from the charge-air distributor (1), place it to one side and seal exposed openings with suitable stop plugs.	Record plug	Fig 4
24	Remove electrical subharness (16) from the charge-air distributor (1).	Dismantling tool	Fig 5
25	Disconnect engine wiring harness for removal of the charge-air distributor (1).		AR15.18-P-1011-01SB
		Screw, engine wiring harness ground line to camshaft housing	*BA15.18-P-1001-01MRT
		Screw, engine wiring harness cable duct to camshaft housing	*BA15.18-P-1002-01MRT
		Screw, engine wiring harness potential distributor to camshaft housing	*BA15.18-P-1003-01MRT
		Dismantling tool	Fig 5
26	Remove screws (15.1 to 15.9) in reverse numerical order.	: Tighten screws (15.1 up to 15.9) in numerical order. Screw/bolt, charge air distributor to cylinder head	*BA09.41-P-1001-01MRT
27	Unscrew screw (7).	Screw/bolt, support to charge air distributor	*BA09.41-P-1018-01MRT
28	Remove charge-air distributor (1) and seal openings with clean rags.	: Replace seals. Assembly tool	Fig 2
29	Remove throttle valve actuator (M16/5).	If the charge air distributor (1) is replaced.	AR07.51-P-1404SB
30	Remove charge air pressure/temperature sensor (B159/2).	If the charge air distributor (1) is replaced.	AR09.41-P-2012SB
31	Remove purge line (12).	If the charge air distributor (1) is replaced. Screw, tank regeneration to charge-air distributor	*BA09.41-P-1014-01MRT
	Clean
32	Clean sealing surfaces on charge-air distributor (1) and cylinder head.	Assembly cleaner	*BR00.45-Z-1028-04A
33	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
	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
34	Perform engine test run. While doing so, check engine for proper operation and leak tightness.