Remove, install resonance intake manifold - AR09.20-P-1961TMG

ENGINE 156.982 in MODEL 209.377 /477

ENGINE 156.983 in MODEL 211.077 /277, 219.377

Fig 1: Identifying Resonance Intake Manifold Components

Courtesy of MERCEDES-BENZ USA

MODIFICATION NOTES

6.8.09

Bolt, intake manifold to cylinder head

*BA09.20-P-1002-01R

	Remove/install
	Risk of explosion caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel and risk of injury to eyes and skin caused by contact with fuel	No fire, sparks, open flames or smoking. Only pour fuels into suitable and appropriately marked containers. Wear protective clothing when handling fuel.	AS47.00-Z-0001-01A
	Risk of injury caused by fingers being pinched or crushed when removing, installing or aligning hoods, doors, trunk lids, tailgates or sliding roof.	Keep body parts and limbs well clear of moving parts.	AS00.00-Z-0011-01A
1	Switch ignition off, remove ignition key (transmitter key).	Vehicles with Keyless Go, code 889: Press Keyless Go start/stop button repeatedly until ignition is switched off. Remove keyless go transmitter card or transmitter key from vehicle and store outside of transmission range (min. 2 m)
2	Open engine hood and raise to vertical position	Model 209	AR88.40-P-1000Q
		Model 211	AR88.40-P-1000T
		Model 219	AR88.40-P-1000TX
3	Remove both intake air ducts
4	Remove front engine cover	Do not tilt front engine cover, but lift upwards vertically otherwise retaining lugs can break off.
5	Remove air filter housing		AR09.10-P-1150TMG
6	Release fuel pressure with pressure hose via service valve		AR07.03-P-1460-01TMG Fig 2
7	Dismount fuel line from fuel distributor (4)	Installation: Install new sealing rings.	*BA07.03-P-1001-01C
8	Disconnect connectors (2) at intake pipe (1) at front
9	Detach vacuum line (3)
10	Detach brake booster vacuum line at connection (11)
11	Remove insulating cover
12	Disconnect connectors for injection valves	Place wiring hardness to side.
13	Remove bolt (6) and purge line (5)		*BA07.03-P-1002-01C
14	Detach vacuum hose (9) from intake manifold (1) or from vacuum unit (13)	Detach hose to vacuum reservoir.
15	Remove vacuum line (10).
16	Disconnect connector (12)
17	Remove bolts (8) from intake pipe (1) then remove intake pipe (1) upwards	Close off intake ports in doing so Injection valves is not damaged. Installation: Clean sealing surfaces; replace gasket and bolts.	*BA09.20-P-1002-01R
18	Install in the reverse order
19	Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns during starting procedure or when working near the engine as it is running Carry out engine test run and check intake manifold (1) for leaks	Secure vehicle to prevent it from moving by itself. Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts. In the event of a leak, determine and eliminate cause, otherwise malfunctions and serious environmental pollution may occur.	AS00.00-Z-0005-01A

INJECTION NOZZLES, INJECTION VALVES, LINES

Number	Designation		Engine 156
BA07.03-P-1001-01C	Union nut, fuel feed line to fuel distributor	Nm	20
BA07.03-P-1002-01C	Bolt connecting fuel distributor to resonance intake manifold	Nm	9

INTAKE MANIFOLD

Number	Designation			Engine 156
BA09.20-P-1002-01R	Bolt, intake manifold to cylinder head	Stage 1	Nm	10
		Stage 2	∠ °	90
		Stage 3	∠ °	10

Fig 2: Identifying Pressure Hose (119 589 04 63 00)

Courtesy of MERCEDES-BENZ USA