2002 C240:  Engine Air Filter Replacement
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Perform all these installs at your own risk.  Know how to use all of your shop equipment, and take necessary safety precautions when performing ANY modifications and or maintenance items to your vehicle.  Seek the advice of a paid professional and do not substitute this publication for the advice of a paid professional.  This product is how we accomplished our installs and is not meant to be carved in stone.  InstallUniversity.com is not responsible for a mistake, misprint, or any other error found in this guide.  This page is my experience and only documented as a reminder for myself for future references if I encounter this problem again.

Symptom(s):  None.  You should perform this general maintenance item every 10,000 miles or sooner depending on driving conditions.
 
Date Repaired:  N/A    Mileage:  N/A

Quote to fix from local MB dealer: 
N/A

Part information, cost, were purchased: 

1. Air filter - XXX - $33.34 - NAPA

Time it took to install:
  15 minutes

Complexity of Install:
  Easy

Tools needed for this install: 

1. Torx 20 screw driver
2. Damp Rag
3. Dry Rag

Install Contributors

1. Jasmel Sidhu

Introduction

This is a general maintenance item that should be replaced at least every 10,000 miles.  It is also important to note that the air filters purchased from the local NAPA store, are the exact same filter Mercedes Benz sales.  The only difference is price; you can save $20 by going to your local NAPA and purchasing the same exact air filters.  I had to place the order for the filter one day, and come back the next morning to pick it up because this is not a usual stock item.  It would be good to order both the air filter and oil filter to cut down on trips to the parts store.
 
The 2002 C240 sedan has two air filters; one for each intake tube.  When you purchase your air filter, and two show up in the box, don't panic.  That is exactly what you need for the installation.
 
Installation Procedure
 
1.  Raise your hood, and locate the front of the engine cover shown in Figure 1.  Lift up on the front of the cover.  Once it pops free, it will still be connected, pull it toward the front of the car.  You may need to remove the oil filler cap to disengage the front engine cover.  If you removed your oil filler cap, please put it back on once the front cover has been removed.  Warning:  If you do remove the oil filler cap, make sure no contaminants fall in the filler neck.
 
2.  Locate the front intake tubes shown in Figure 2.  Detach the intake tubes from the air filter housing assembly by pulling back on the front intake tube where it meets the air filter housing.  The arrows in Figure 2 show where to grab, and pull toward the front of the car.  Figure 3 shows the front intake tubes detached from the air filter housing assembly.
 
3.  Grab hold on one side of the air filter housing, I always choose the passenger side, and pull up on the housing (see Figure 4).  Don't be shy about doing this.  It takes some effort to pop the assembly free, but once it pops free, it comes right off.  Be very careful with the air filter assembly.  Warning:  Stay away from the screen housing on the back side of the engine once the air filter assembly is removed from the top of the engine shown in Figure 5.  This goes directly into the engine and is near the mass air flow (MAF) housing.  The MAF sensor is VERY expensive to replace and is a must for your car to run.  No big deal, just stay away from it.
 
4.  Flip the air box filter assembly over and remove the eight torx 20 (T20) screws shown in Figure 6.  The screws do not back all the way out, they will loosen up but remain in the filter housing bottoms.  Lift the lids off and remove the air filters.  You may need to empty the trash in the bottom of the filter can, and wipe the housing out with a damp rag.  Just be sure everything is dry before you put it back together.  See what we found in one of our air filter housings in Figure 7.
 
5.  Replace the air filters in the filter housings.  Be sure you seat the filter gaskets correctly in the housings.  Just be sure the filter gasket bottoms out in the air filter box.
 
6.  Tighten the torx T20 screws (see Figure 8) to snug, I do not have a torque specification.  You may notice that your housing bottom doesn't match up well with the filter housing main body (see Figure 9).  This evidently is normal and as long as the housings touch where the torx screws are, you should be fine.  Heat may be warping the housings, but that is just a guess at this point.
 
7.  Locate the four metal mount clips on the underside of the air filter box housing shown in Figure 10.  Locate the four bulbs on top of the engine shown in Figure 11.  The four metal mount clips on the underside of the air filter assembly have to clip onto the four bulbs on top of the engine.  This is an easy process and takes just a second to get the alignment correct.  Once you have the alignment set, just push the cover down.  The cover should pop into place immediately.  Go over each corner of the air box assembly twice, make one round then another, pressing down to make sure the assembly is seated correctly.
 
8.  Reattach the front intake air tubes shown in Figure 12.
 
9.  Reinstall the front engine cover by sliding the back part of the cover into the slots on top of the air filter housing assembly as shown in Figure 13.  You may need to remove the oil filler cap to snap the front cover back on.  If you remove your oil filler cap, please put it back on once the front cover has been installed.  Warning:  If you do remove the oil filler cap, make sure no contaminants fall in the filler neck.
 
10.  Smile!  Your done!!  Doesn't it feel nice that you saved yourself a bunch of money and know the job is done correctly?
 
11.  If you have a NAPA parts store nearby, you may want to consider purchasing your air filter from NAPA instead of your local Mercedes Benz dealership.  The filter is the same exact filter and cost $20 less at NAPA.  Check out Figure 14 for the filter comparison.  

Click on the photographs to enlarge them.

Figure 1
front engine cover tn

Figure 2
 
front tube locate tn

Figure 3
front tube tn

Figure 4
assembly removal tn

Figure 5
mafs tn

Figure 6
airbox open tn

Figure 7
cig bud tn

Figure 8
airbox open tn

Figure 9
filter cover tn

Figure 10
mount clips tn

Figure 11
bulb tn

Figure 12
front tube tn

Figure 13
front engine cover tn

Figure 14
filter comparison tn