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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)
G10108387Courtesy of MERCEDES-BENZ USA
Fig 2: Identifying Intake Manifold Remove/Install Components (2 Of 3)
G10108388Courtesy of MERCEDES-BENZ USA
Fig 3: Identifying Intake Manifold Remove/Install Components (3 Of 3)
G10108389Courtesy 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 
REMOVINGINSTALLING Remove/install     
DANGER 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
    IMPORTANT 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 IMPORTANT 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) NOTES To prevent leaks and damage, do not kink or bend the high pressure lines (11).
INSTALLATION IMPORTANT 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
TORQUE SPECIFICATION *BA07.03-P-1001-01E 
TORQUE SPECIFICATION *BA07.03-P-1002-01E 
TORQUE SPECIFICATION *BA07.03-P-1003-01E 
TORQUE SPECIFICATION *BA07.03-P-1004-01E 
TORQUE SPECIFICATION *BA07.03-P-1005-01E 
TORQUE SPECIFICATION *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 TORQUE SPECIFICATION *BA09.41-P-1010-01O 
14 Remove charge air ducts   AR09.41-P-8620MMB 
15 Drain coolant at radiator   AR20.00-P-1142MM
NOTES 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 TORQUE SPECIFICATION *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)  
TORQUE SPECIFICATION *BA13.25-P-1003-01Y 
19.2 Remove guide pulley with bracket on timing case cover Vehicles with AIRmatic  
TORQUE SPECIFICATION *BA13.25-P-1003-01Y 
20 Detach coolant return line (21) on oil filter housing TORQUE SPECIFICATION *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 TORQUE SPECIFICATION *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 TORQUE SPECIFICATION *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 TORQUE SPECIFICATION *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 INSTALLATION IMPORTANT Replace sealing ring on hose fitting (29).  
TORQUE SPECIFICATION *BA09.41-P-1007-01O 
28 Remove bolts (30) for intake manifold (1) on cylinder heads TORQUE SPECIFICATION *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  
IMPORTANT To do this remove bolts (31) for charge air cooler (2) on intake manifold (1) and loosen clamp on throttle valve actuator.  
TORQUE SPECIFICATION *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
DANGER 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
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