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

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ENGINE 120.980/981 

Fig 1: Identifying Intake Manifold Remove/Install Components (1 Of 2)
G04678465Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 2: Identifying Intake Manifold Remove/Install Components (2 Of 2)
G04678466Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
REMOVINGINSTALLING Removing, installing     
1 Remove air cleaner, install   AR09.10-P-1050F 
2 Remove electronic accelerator actuator together with throttle valve body, install   AR30.20-P-1262F
3 Remove cover of cable duct over intake manifold    
4 Remove covers (20) of the high voltage distributors IMPORTANT Use screwdriver to release catch (arrow) for this step  
5 Disconnect all the plug connections of the cables which run over the intake manifold, and of the electrical components at the intake manifold    
6 Detach vacuum lines of the components located at the intake manifold IMPORTANT Pay attention to color coding of vacuum lines  
    Connection diagram of intake manifold AR09.20-P-1310-01F 
7 Detach bowden cable (30) at throttle control relay lever (6) IMPORTANT Remove guide piece (27) for this step, install. First of all, pull plastic nipple out of guide piece. When installing, ensure that the plastic nipple properly engages in the guide piece.  
8 Press together plastic clip (28) and pull out of bracket (10) together with bowden cable (30)    
9 Detach control pressure bowden cable (98)    
10 Release fuel pressure through service valve at fuel rail See Diagnosis Manual Engine, Volume 2, Index 3.2  
    SPECIAL TOOL Figure
    SPECIAL TOOL Fig 4
11 Disconnect fuel feed line (17/3) and fuel return flow line (17/2) IMPORTANT Collect fuel  
12 Unscrew bolts (14)    
13 Disconnect vacuum lines for brake unit at right and left sides of intake manifold    
14 Disconnect lines of exhaust gas recirculation on left and right at intake manifold    
15 Remove air collecting box, install Model 140 
See Repair Instructions Automatic Heater
Model 140, op. no. 83-140		  
16 Unscrew bolts (15) IMPORTANT Tighten bolt from the middle to the outside. Pay attention to different bolt lengths.  
    TORQUE SPECIFICATION *BA09.20-P-1001-01C 
17 Raise intake manifold (19) and take off to the front INSPECT Use straightedge to inspect flange surfaces; process on dressing plate if necessary.
IMPORTANT When installing, ensure that no vacuum lines and electric cables are jammed in between		  
18 Remove intermediate flange (19/1) TORQUE SPECIFICATION *BA09.20-P-1002-01C 
    INSPECT Replace if necessary  
    IMPORTANT Replace shaped seals (18/1)  
REFER TO COMPONENT MODIFICATIONS Metal intermediate flange replaces rubber intermediate flange   BT09.20-P-0001-01A 
19 Replace gaskets (18) IMPORTANT Gaskets should engage in locking sleeves (17)  
19 Install in the reverse order    
20 Adjust throttle control   AR30.10-P-1010F
21 Inspect idle speed, set See Diagnosis Manual Engine Volume 1  
TORQUE SPECIFICATION INTAKE MANIFOLD

Number Designation Engine 120
BA09.20-P-1001-01C Bolt of intake manifold to cylinder head Nm 28
BA09.20-P-1002-01C Bolt of intermediate flange to cylinder head Nm 28
Fig 3: Identifying Tester (103 589 00 21 00)
G04678467Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 4: Identifying Pressure Hose (119 589 04 63 00)
G04678468Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
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