(Remove/Install Charge Air Line - AR09.41-P-8950SBA)

Engine 256.8 in model 223 

MODIFICATION NOTES

14.03.2023

Document completely revised.

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  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	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
	Remove/install
1	Remove upper charge air line.		AR09.41-P-7457S
2	Release and disconnect the electrical connector (2).
3	Release and disconnect electrical connectors (3, 4).
4	Expose electric line (5).	Dismantling tool	Fig 3
5	Remove wide open throttle bleed line (6) from charge air line (1).	Replace sealing ring. Assembly tool	Fig 1
		Record plug	Fig 5
6	Open clamp (7) and remove air intake line (8) from charge air line (1).	Align marking of the air intake line (8) with marking on charge air line (1). Replace air intake line (8). Set of protective covers	Fig 4
7	Remove screws (9, 10).	Screw, charge air line to timing case	*BA09.41-P-1004-01MRT
		Screw, charge air line to additional compressor	*BA09.41-P-1006-01MRT
8	Remove screws (11, 12).	Screw, charge air line bracket to throttle valve actuator	*BA09.41-P-1005-01MRT
9	Remove charge air pressure/temperature sensor (B159/1).		AR09.41-P-2014SBA
10	Release clamp (13).	Screw clamp, boot to exhaust gas turbocharger	*BA09.41-P-1010-01MRT
11	Unscrew screws (14, 15, 16) in reverse numerical order.	Screw/bolt, charge air line to chain case cover	*BA09.41-P-1002-01MRT
12	Unscrew screws (17, 18, 19, 20) in reverse numerical order.	Screw/bolt, charge air line to chain case cover	*BA09.41-P-1002-01MRT
13	Remove brackets (21, 22).
14	Remove charge air line (1) together with check valve (23) and lower charge air line (24).	Set of protective covers	Fig 2
15	Remove charge air line (1) from check valve (23).	Align mark of check valve (23) with mark of charge air line (1). Replace seal.
16	Open clamp (25) and remove charge air hose (26).	Align mark of charge air hose (26) with mark on charge air line (1). Screw clamp, boot to exhaust gas turbocharger	*BA09.41-P-1010-01MRT
17	Remove overrun mode bypass air switchover valve (Y101).	When replacing the charge air line (1).	AR09.40-P-3000SBA
18	Install in the reverse order.

CHARGE AIR PIPE/CHARGE AIR COOLING

Number	Designation		Engine 256
BA09.41-P-1002-01MRT	Screw/bolt, charge air line to chain case cover	Nm	8

CHARGE AIR PIPE/CHARGE AIR COOLING

Number	Designation		Engine 256
BA09.41-P-1004-01MRT	Screw, charge air line to timing case	Nm	8

CHARGE AIR PIPE/CHARGE AIR COOLING

Number	Designation		Engine 256
BA09.41-P-1005-01MRT	Screw, charge air line bracket to throttle valve actuator	Nm	8

CHARGE AIR PIPE/CHARGE AIR COOLING

Number	Designation		Engine 256
BA09.41-P-1006-01MRT	Screw, charge air line to additional compressor	Nm	8

CHARGE AIR PIPE/CHARGE AIR COOLING

Number	Designation		Engine 256
BA09.41-P-1010-01MRT	Screw clamp, boot to exhaust gas turbocharger	Nm	6

Fig 1: Identifying Assembly Tool (000 589 93 63 00)

Courtesy of MERCEDES-BENZ USA

Fig 2: Identifying Set Of Protective Covers (001 589 12 91 00)

Courtesy of MERCEDES-BENZ USA

Fig 3: Identifying Dismantling Tool (000 589 95 63 00)

Courtesy of MERCEDES-BENZ USA

Fig 4: Identifying Set Of Protective Covers (001 589 01 91 00)

Courtesy of MERCEDES-BENZ USA

Fig 5: Identifying Record Plug (129 589 00 91 00)

Courtesy of MERCEDES-BENZ USA