Remove/install intake manifold - AR09.20-P-1310GZ (ML500)

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ENGINE 113.964 in MODEL 164.175

Fig 1: Identifying 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 as well as 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 jammed or pinched when removing, installing or aligning hoods, doors, trunk lid/rear-end door or sliding roof.	When moving components, ensure that no body parts or limbs are within operating range of moving parts.	AS00.00-Z-0011-01A
1	Switch ignition off, remove ignition key (transmitter key).	On vehicles with code 889 Keyless Go: Press Keyless Go start/stop button repeatedly until the ignition is switched off. Remove the Keyless Go transmitter card or transmitter key from the vehicle and store beyond the reach of the transmitter (at least 2 m).
2	Open engine hood and raise to vertical position		AR88.40-P-1000GZ
3	Remove air filter housing		AR09.10-P-1150GZ
4	Remove hot film mass air flow sensor with air intake pipe		AR07.07-P-1454GZ
5	Dismount fuel line (3) from fuel distributor		*BA07.52-P-1001-01A
6	Removing fuel rail with injection valves		AR07.03-P-1451GZ
			*BA07.52-P-1002-01A
7	Remove vacuum lines from intake manifold (1) and variable intake manifold switchover valve (Y22/6)	Installation: Observe intake manifold connection diagram.	AR09.20-P-1310-01GZ
8	Disconnect electrical connector at variable intake manifold switchover valve (Y22/6)
9	Screw down union nut (5) on line to exhaust gas recirculation valve (4)	Counterhold connection fitting when unscrewing.
10	Remove combination valves (6)
11	Remove intake manifold (1) bolts on cylinder head		*BA09.20-P-1001-01D
12	Remove intake manifold (1) upwards	Plug intake ducts. The intake manifold must not be disassembled. Installation: Replace seals (2). When mounting observe correct seating of bore for combination valve (see arrow). Installation: Use centering pin to achieve exact bottoming of intake manifold as well as centering of seals (2).
		Set of dowel bolts	Fig 2
13	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 a running engine	Secure vehicle to prevent it from moving by itself. Wear closed and snug-fitting work clothes. Do not grasp hot or rotating parts.	AS00.00-Z-0005-01A
14	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.

FUEL RAIL

Number	Designation		Engines 113.940/941/942/943/944/945/946/948/960/961/962/963/964/965/966/967/968/969/971/980/981/982/984/986/988
BA07.52-P-1001-01A	Disconnect fuel feed line at fuel rail	Nm	38
BA07.52-P-1002-01A	Bolt, fuel rail to intake manifold	Nm	10

INTAKE MANIFOLD

Number	Designation			Engines 112, 113
BA09.20-P-1001-01D	Bolt, intake manifold to cylinder head	M8	Nm	20

Fig 2: Identifying Set Of Dowel Bolts (112 589 02 62 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.