Remove/install intake manifold - AR09.20-P-1310MMB

ENGINES 157, 278 in MODEL 216, 221

Fig 1: Identifying Intake Manifold Remove/Install Components (1 Of 3)

Courtesy of MERCEDES-BENZ USA

Fig 2: Identifying Intake Manifold Remove/Install Components (2 Of 3)

Courtesy of MERCEDES-BENZ USA

Fig 3: Identifying Intake Manifold Remove/Install Components (3 Of 3)

Courtesy of MERCEDES-BENZ USA

MODIFICATION NOTES

27.7.10	Value changed: Fuel line union nut on fuel distributor		*BA07.03-P-1001-01E
	Value changed: Fuel line union nut on high-pressure pump		*BA07.03-P-1002-01E

	Remove/install
	Risk of injury caused by fingers being pinched or crushed when removing, installing or aligning hoods, doors, trunk lids, liftgates or sliding roof	Keep body parts and limbs well clear of moving parts.	AS00.00-Z-0011-01A
		The ground line on the battery must always be detached before beginning work on the fuel system otherwise pressure will be lost in the fuel system through opening a vehicle door or the trunk lid
1	Remove ME-SFI [ME] control unit (N3/10)		AR07.08-P-7008MMB
2	Remove both air filter housings (5)
3	Remove insulation between air filter housings (5) and cylinder head cover
4	Remove firewall (3)
5	Remove crash plate on high-pressure pumps and remove insulation from high-pressure pumps		AR07.02-P-1020MMB
6	Detach vacuum line (8) for brake booster on vacuum pump and intake manifold (1)		AR43.05-P-1320MMB
7	Detach vacuum line (7) for centrifuge on intake manifold (1)		AR01.20-P-2100MMB
8	Disconnect engine wiring harness on intake manifold (1) and cylinder head covers and lay down to the rear	The electrical line for actuation of the A/C compressor remains on the A/C compressor.	AR01.00-P-2410-02MMB
9	Remove high-pressure lines (11)	To prevent leaks and damage, do not kink or bend the high pressure lines (11). The sealing cone for the high-pressure lines (11) must be checked before assembly. The work instructions absolutely must be observed for assembly work. A leak test on the high-pressure fuel circuit must be carried out after assembly: ↓
		Check sealing cone on high-pressure lines (11).	AR07.03-P-1010-03MM
		Mount high-pressure lines (11).	AR07.03-P-1010-02MMB
		Check fuel high pressure circuit.	AR07.03-P-1010-04MM
			*BA07.03-P-1001-01E
			*BA07.03-P-1002-01E
			*BA07.03-P-1003-01E
			*BA07.03-P-1004-01E
			*BA07.03-P-1005-01E
			*BA07.03-P-1006-01E
		Cleaner from package	*BR00.45-Z-1028-04A
10	Disconnect electrical line (4) on intake manifold (1)
11	Detach purge line (10) on intake manifold (1)
12	Detach vacuum line (6) for boost pressure regulator (Y77/1) on vacuum pump
13	Detach boost pressure regulator (Y77/1) with bracket on intake manifold (1) and lay down to the front		*BA09.41-P-1010-01O
14	Remove charge air ducts		AR09.41-P-8620MMB
15	Drain coolant at radiator		AR20.00-P-1142MM
	Notes on coolant		AH20.00-N-2080-01A
16	Disconnect bleed line (20) for charge air cooler (2) at connecting point
17	Detach clamp for bleed line (20) on ABC pump carrier or guide pulley		*BA09.41-P-1004-01O
18	Remove poly-V belt		AR13.20-P-0001MMB
19.1	Detach ABC pump with bracket on timing case cover and place with attached lines to one side	Vehicles with code (487) Active Body Control (ABC)
19.1			*BA13.25-P-1003-01Y
19.2	Remove guide pulley with bracket on timing case cover	Vehicles with AIRmatic
19.2	Remove guide pulley with bracket on timing case cover		*BA13.25-P-1003-01Y
20	Detach coolant return line (21) on oil filter housing		*BA09.41-P-1006-01O
21	Detach coolant return line (21) on coolant hose (22)
22	Detach coolant return line (23) on timing case cover		*BA09.41-P-1006-01O
23.1	Detach clamp for coolant feed line (24) on oil dipstick guide tube (25)	Vehicles without 4MATIC
23.2	Detach clamp for coolant feed line (24) on the front cover	Vehicles with 4MATIC
24	Detach lower bracket (28) for coolant feed line (24) on timing case cover		*BA09.41-P-1005-01O
25	Detach coolant feed line (24) on coolant hose (27)
26	Detach upper bracket (26) for coolant feed line (24) on timing case cover		*BA09.41-P-1005-01O
27	Remove bolt for hose fitting (29) for bleed line (20) on timing case cover and pull hose fitting (29) out of the timing case cover	Replace sealing ring on hose fitting (29).
27			*BA09.41-P-1007-01O
28	Remove bolts (30) for intake manifold (1) on cylinder heads		*BA09.41-P-1011-01O
29	Lift intake manifold (1)
30	Disconnect electrical line (9) on front knock sensors
31	Unclip electrical line (9) for front knock sensors on intake manifold (1)
32	Remove intake manifold (1) upwards
33	Detach detachable parts from intake manifold (1)	If necessary
		To do this remove bolts (31) for charge air cooler (2) on intake manifold (1) and loosen clamp on throttle valve actuator.
			*BA09.41-P-1001-01O
34	Install in the reverse order
35	Inspecting cooling system for leaks		AR20.00-P-1010SX
36	Read out fault memory with STAR DIAGNOSIS and erase if necessary		AD00.00-P-2000-04A
	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
37	Carry out an engine test run and check intake tract and fuel system for leaks

CHARGE AIR PIPE/CHARGE AIR COOLING

Number	Designation		Engine 157	Engine 278
BA09.41-P-1001-01O	Bolt, charge air cooler to charge air distribution line	Nm	9	9
BA09.41-P-1004-01O	Bolt, low temperature line clamp to bracket	Nm	9	9
BA09.41-P-1005-01O	Bolt, feed line to timing case cover	Nm	9	9
BA09.41-P-1006-01O	Bolt, coolant line to timing case cover/oil filter housing	Nm	9	9
BA09.41-P-1007-01O	Bolt, bleed lines hose fitting to timing case cover	Nm	9	9
BA09.41-P-1010-01O	Bolt, pressure transducer holder to charge air distribution line	Nm	5	5
BA09.41-P-1011-01O	Bolt, charge air distribution line to cylinder head	Nm	9	9

BELT TENSIONING DEVICE

Number	Designation		Engine 157	Engine 278
BA13.25-P-1003-01Y	Bolt, guide pulley carrier/ABC pump to timing case cover/coolant pump	Nm	20	20

INJECTORS, INJECTION VALVES, LINES

Number	Designation		Engine 157	Engine 278
BA07.03-P-1001-01E	Union nut, fuel line to fuel distributor	Nm	22	22
BA07.03-P-1002-01E	Union nut, fuel line to high-pressure pump	Nm	22	22
BA07.03-P-1003-01E	Bolt, fuel line service valve to cylinder head cover	Nm	9	9
BA07.03-P-1004-01E	Bolt, right bracket for fuel line clamp to high pressure pump drive housing/cylinder head	Nm	14	14
BA07.03-P-1005-01E	Bolt, left bracket for high pressure line clamp to cylinder head cover/cylinder crankcase	Nm	9	9
BA07.03-P-1006-01E	Bolt, fuel line clamp to charge air distribution line	Nm	6	6

REPAIR MATERIALS

Number	Designation	Order number
BR00.45-Z-1028-04A	Cleaner from package	Adolf Wurth GmbH & Co. KG