Remove/install charge air line from check valve to throttle valve actuator

AR09.41-P-8951MRT

Remove/install charge air line from check valve to throttle valve actuator

28.03.2018

Engine

256.9 in model 222

1

Electrical wiring harness

4

Screw

8

Screw

2

Screw clamp

5

Charge air line

B28/26

Pressure and temperature sensor upstream of throttle valve

3

Screw clamp

6

Boot

2

Screw clamp

3

Screw clamp

4

Screw

5

Charge air line

6

Boot

7

Check valve

 Caution

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

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-P-5000-01A



Remove

1

Remove charge-air distributor.

AR09.41-P-8683MRT

2

Drain off coolant.

AR20.00-P-1142MRT

3

Remove rear engine mount from engine carrier.

AR22.10-P-1160MRT

 Do not remove engine carrier.

4

Lift transmission and support from below with suitable tool.



000 588 10 62 00 Support plate

WS26.00-P-3309B



000 588 11 62 00 Major assembly mount

WS01.00-P-0092B

5

Remove mounting plate and major assembly mount from working area.



000 588 10 62 00 Support plate

WS26.00-P-3309B



000 588 11 62 00 Major assembly mount

WS01.00-P-0092B

6

Lower vehicle.

7

Remove vacuum line of brake booster.

8

Remove screw (8).

9

Remove electrical wiring harness (1) from partition and place to one side.

10

Remove center partition.

11

Remove coolant hose at partition and seal openings with protective covers.

AR20.20-P-7441-01RQ

 Set of protective caps

*001589009100

12

Release screw clamps (2, 3).

13

Remove pressure and temperature sensor upstream of throttle valve (B28/26).

AR07.04-P-0091MRT

14

Unscrew bolt (4).

15

Remove charge air line (5) from boot (6).

16

Remove charge air line (5) toward front.

17

Remove boot (6) from check valve (7) and remove upwards.



Install

18

Slide boot (6) onto check valve (7) up to end stop.

 Installation: Replace boot (6).

Lubricant, rubber assembly 1 l

*BR00.45-Z-1010-06A

19

Align marking (arrow A) of new boot (6) with marking (arrow B) of check valve (7).

20

Tighten screw clamp (3).

 Screw clamp, boot between charge air lines

*BA09.41-P-1009-01MRT

21

Install charge air line (5).

Lubricant, rubber assembly 1 l

*BR00.45-Z-1010-06A

22

Tighten down screw/bolt (4).

 Screw/bolt, charge air line to chain case cover

*BA09.41-P-1002-01MRT

23

Tighten screw clamp (2).

 Screw clamp, boot between charge air lines

*BA09.41-P-1009-01MRT

24

Install pressure and temperature sensor upstream of throttle valve (B28/26).

AR07.04-P-0091MRT

25

Install coolant hose at partition.

AR20.20-P-7441-01RQ

26

Install center partition.

27

Install electrical wiring harness (1) at partition.

28

Tighten screw (8).

 M61

*BA00.10-P-1002-04A

29

Install vacuum line of brake booster.

30

Raise vehicle.

31

Lift transmission and remove suitable tool.



000 588 10 62 00 Support plate

WS26.00-P-3309B



000 588 11 62 00 Major assembly mount

WS01.00-P-0092B

32

Remove mounting plate and major assembly mount from working area.



000 588 10 62 00 Support plate

WS26.00-P-3309B



000 588 11 62 00 Major assembly mount

WS01.00-P-0092B

33

Install rear engine mount on engine carrier.

AR22.10-P-1160MRT

34

Fill in coolant.

AR20.00-P-1142MRT

35

Install charge-air distributor.

AR09.41-P-8683MRT

 Metric screws/bolts and nuts as per MBN 10 105, 10 143

Number

Designation

8.8

10.9

BA00.10-P-1002-04A

M61

Nm

9

13

 Charge air pipe/charge air cooling

Number

Designation

Engine 256.9

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 256.9

BA09.41-P-1009-01MRT

Screw clamp, boot between charge air lines

Nm

4

Repair materials

Number

Designation

Order number

BR00.45-Z-1010-06A

Lubricant, rubber assembly 1 l

A 000 989 03 67