Removing and installing intake manifold - AR09.20-P-1310E

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ENGINE 119.97

Fig 1: Identifying Intake Manifold Remove/Install Components

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

	Removing, installing
1	Remove air cleaner, install		AR09.10-P-1050E
2	Partially drain coolant
3	Unplug al the plug connections of the cables which run across the intake manifold or of the electrical components at the intake manifold
4	Unclip guide rail for ignition cables
5	Detach vacuum lines of the components located at the intake manifold	Pay attention to color coding of vacuum hoses
		Connection diagram of intake manifold	AR09.20-P-1310-01E
	Risk of explosion	Pay attention to accident prevention regulations!
6	Release fuel pressure through service valve at the fuel rail	See Diagnosis Manual Engine, Volume 2, Index 3.1
			Fig 2
			Figure
7	Unbolt fuel feed line (17/3) and return flow line (17/2)	Collect fuel
8	Disconnect vacuum line for brake unit		Fig 4
9	Remove guide piece (27)	Removal : pull plastic nipple out of guide piece. Do not damage guide piece. Installation : ensure that the plastic nipple engages properly in the guide piece.
10	Detach bowden cable (30) at throttle control lever (9)
11	Pull bowden cable (30) out of fix lever (10)	Removal : press together plastic clip (28)
12.1	Detach control pressure bowden cable (98)	AT
13	Separate plug connection of electronic accelerator actuator (M16/1x1) and detach cable	Ensure the electric cable of the electronic accelerator actuator is correctly routed: ↓
		Model 124.036 up to 06/93	AR30.20-P-1262-01A
		Model 124.034	AR30.20-P-1262-01B
		Model 124.036 as of 07/93	BT30.20-P-0001-01A
14	Disconnect coolant hose (33) at front of intake manifold
15	Disconnect coolant hose at rear of intake manifold
16	Unscrew bolts (14, 15, 16)	Pay attention to different lengths of bolts and different spacers (13). Oil bolt threads with assembly oil. Tighten bolts according to tightening diagram: ↓
		Tightening diagram of intake manifold attachment	AR09.20-P-1310-03E
			*BA09.20-P-1001-01C
17	Take off intake manifold (19)	When installing, ensure that no vacuum lines and electric cables are jammed in between and that the intake manifold engages in the dowel pins.
18	Use straightedge to inspect flange surfaces	If necessary, process on dressing plate, or: ↓
		replace intake manifold	AR09.20-P-1310-04E
19	Replace gaskets (18)
20	Install in the reverse order
21	Adjust throttle control	With ASR code 471a	AR30.10-P-1010EA
		Without ASR code 471a	AR30.10-P-1010EB
22	Inspect idle speed, set	See Diagnosis Manual Engine Volume 1

INTAKE MANIFOLD

Number	Designation		Engine 119
BA09.20-P-1001-01C	Bolt of intake manifold to cylinder head	Nm	28
BA09.20-P-1003-01C	Bolt of top part of intake manifold to bottom part of intake manifold	Nm	25

Fig 2: Identifying Tester (103 589 00 21 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 3: Identifying Pressure Hose (119 589 04 63 00

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 4: Identifying Ring Wrench Bit (000 589 70 03 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.