Remove, Install Intake Manifold - Ar09.20-P-1310L: Notes

Engine 137.970 In Models 215.378, 220.178 /878

Fig 1: Identifying Intake Manifold Remove/Install Components (1 Of 2)

Fig 2: Identifying Intake Manifold Remove/Install Components (2 Of 2)

	Removing, installing
	Risk of injury to skin and eyes from scalding with hot coolant which splashes out. Risk of poisoning from swallowing coolant.	Do not open cooling system unless coolant temperature is below 90°C. Open cap slowly and release the pressure. Do not pour coolant into beverage bottles. Wear protective gloves, protective clothing and eye protection.	AS20.00-Z-0001-01A
	Notes on coolant	All engines.	AH20.00-N-2080-01A
1	Remove air cleaner		AR09.10-P-1050L
2	Remove ECI mains unit (N91)
3	Detach coolant vent line (7) at thermostat housing and remove cover (4)	Collect coolant which flows out in a suitable vessel.
4	Disconnect crankcase ventilation hose (2) at couplings (A) and (B)	Removal: Remove crankcase ventilation hose (2).
5	Remove switchover valves (Y32/1) and (Y32/2)
		Intake manifold M137 connection diagram	AR09.20-P-1310-01L
		Intake manifold M137 connection diagram	AR09.20-P-1310-01LA
6	Release fuel pressure through service valve (1/1)	Collect fuel.
			Fig 3
			Figure
7	Unscrew fuel feed line (17/2) at fuel distributor (17)	Collect fuel.
			*BA07.52-P-1001-01A
8	Unscrew fuel feed line (17/2) mounting clamp at left cylinder head cover	Removal: It is not permissible to bend fuel feed line out of the way. There is a risk of splits forming at the fuel rail, and also at the fuel feed line.
9	Remove hot film mass air flow sensor (B2/5)		AR07.07-P-1453L
10	Remove electronic accelerator actuator (M16/6) together with flap connection	Disconnect vacuum lines (5, 6).	AR30.20-P-1262L
11	Disconnect electrical connectors	Cylinder shutoff valve cylinders 10-12 (Y81/1), camshaft Hall sensor (B6/2) on left and (B6/3) on right, coolant temperature sensor (B11/4), intake air temperature sensor (B17), right variable camshaft timing solenoid (Y49/2) and injectors (Y62).
12	Unscrew engine wiring harness at intake manifold	Unscrew bolts (8), (2 x). Replace mounting clip.
13	Remove engine wiring harness from firewall and place to the side
14	Remove rubber mount (9)
15	Unscrew bolts (19/1) (14 x)		*BA09.20-P-1001-01G
16	Remove complete intake manifold (19) with intake fittings (1), intake air pipes (3) and fuel distributor (17).	Removal: Seal intake ports. Do not disassemble the intake manifold. Do not reuse the screws (19/1). Installation: In the event of engine damage, be sure to check for and, if applicable, remove any metal chips inside the intake manifold.
17	Replace seals (19/3)	Installation: Fix seals (19/3) in place at cylinder head using stud bolts.
18	Install in the reverse order
19	Adjust coolant to correct level	Cooling system is bled automatically

Fuel Rail

Number	Designation		Engine 137
BA07.52-P-1001-01A	Fuel feed line to fuel rail	Nm	38

Intake Manifold

Number	Designation				Engine 137
BA09.20-P-1001-01G	Bolt, intake manifold on cylinder head	1st stage	M6	Nm	8
		1st stage	M8	Nm	20
		2nd stage	M6	Nm	8
		3rd stage	M6	∠°	90

Fig 3: Identifying Tester (51 103 589 00 21 00)

Fig 4: Identifying Pressure Hose (119 589 04 63 00)