Remove, install resonance intake manifold - AR09.20-P-1961GZS (ML63 AMG)

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ENGINE 156 in MODEL 164, 251

Fig 1: Identifying Resonance Intake Manifold Remove/Install Components

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

	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 164	AR88.40-P-1000GZ
		Model 251	AR88.40-P-1000RT
3	Remove partition wall between wheelhouses	Model 251	AR62.30-P-2400RT
4	Remove air filter housing	Do not tilt front engine cover, but lift upwards vertically otherwise retaining lugs can break off.	AR09.10-P-1150GZS
5	Release fuel pressure with pressure hose via service valve		AR07.03-P-1460-01TMG
		Pressure hose	Fig 3
6	Dismount fuel line from fuel distributor (4)	Installation: Install new sealing rings.
			*BA07.03-P-1001-01C
7	Disconnect connectors (2) at intake pipe (1) at front
8	Detach vacuum line (3)
9	Detach brake booster vacuum line at connection (11)
10	Remove insulating cover
11	Disconnect connectors for injection valves	Place wiring hardness to side.
12	Remove bolt (6) and place purge line (5) to one side		*BA07.03-P-1002-01C
13	Detach vacuum hose (9) from intake manifold (1) or from vacuum unit (13)	Detach hose to vacuum reservoir.
14	Remove vacuum line (10).
15	Unscrew fuel line (7) from intake pipe (1)
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.
	Installation: Observe tightening pattern for fastening the intake manifold.		Fig 2
			*BA09.20-P-1002-01R
18	Install in the reverse order
	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	Secure vehicle to prevent it from moving by itself. Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts.	AS00.00-Z-0005-01A
19	Carry out engine test run and check intake manifold (1) for leaks	In the event of a leak, determine and eliminate cause, otherwise malfunctions and serious environmental pollution may occur.

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	8
		Stage 2	Nm	10
		Stage 3	∠°	90

Fig 2: Identifying Tightening Sequence Of Intake Manifold Bolts

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

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

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.