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

ENGINES 152.9 in MODEL 172.4 

Fig 1: Identifying Intake Manifold Remove/Install Components (1 Of 2)

Courtesy of MERCEDES-BENZ USA

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

Courtesy of MERCEDES-BENZ USA

	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 built up in the fuel system through opening a vehicle door or the trunk lid
1	Detach ground line from battery		AR54.10-P-0003W
	Notes on battery		AH54.10-P-0001-01A
2	Remove ME-SFI [ME] control unit		AR07.08-P-7008MMI
3	Disconnect electrical connector for vehicle wiring harness		AR01.00-P-2410-02MMI
4	Unclip bracket of the vehicle wiring harness on bracket of the ME-SFI [ME] control unit and engine suspension lug and place vehicle wiring harness to one side		AR01.00-P-2410-02MMI
5	Remove both soundproofing (6) on high-pressure pumps and on cylinder head cover
6	Disconnect electrical connection on A/C compressor and unclip associated wiring harness on engine
7	Disconnect electrical connection on coolant thermostat and unclip associated wiring harness on engine
8	Disconnect electrical connector on power steering pump
9	Detach engine wiring harness on LH front cover
10	Detach brackets for engine wiring harness on the RH cylinder head cover		AR01.00-P-2410-02MMI
11	Unclip starter wiring harness on intake manifold (1) and cylinder head and place to one side
12	Detach engine wiring harness on LH cylinder head cover and on intake manifold (1) and place to one side		AR01.00-P-2410-02MMI
13	Reduce fuel pressure through service valve	Open tank cap for a short time in order to remove the overpressure in the fuel tank.	AR07.03-P-1460-01VA
			*BA07.03-P-1007-01E
			Fig 3
14	Unclip bleed line (5) at the front on intake manifold (1)
15	Remove intake air temperature sensor (B17)
16	Detach hose (7) for centrifuge on air duct housing (8)
17	Unclip air duct housing (8) on throttle valve actuator and place with attached bleed line (5) to one side	Ensure that seal is seated correctly.
18	Detach vacuum line from brake booster on intake manifold (1) and vacuum pump and place to one side
19	Detach purge line (9) on throttle valve actuator and on cylinder head cover
20	Disconnect electrical connection on throttle valve actuator and unclip electrical line
21	Remove high-pressure lines (2, 4) and low-pressure line (3)	Do not kink or bend high-pressure lines (2, 4) and low-pressure line (3). Leaks and damage can occur otherwise. The sealing cone of the high-pressure lines (2, 4) and the low-pressure line (3) 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 (2, 4) and low-pressure line (3).	AR07.03-P-1010-03MM
		Mount high-pressure lines (2, 4) and low-pressure line (3)	AR07.03-P-1010-02MMI
		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-1006-01E
			*BA07.03-P-1007-01E
			*BA07.03-P-1008-01E
			*BA07.03-P-1009-01E
		Cleaner from package	*BR00.45-Z-1028-04A
22	Unclip oil line (11) for cylinder deactivation auxiliary oil pump on intake manifold (1)
23	Remove bolts (13) on intake manifold (1)	Observe tightening sequence for assembly: ↓
		Tightening sequence for intake manifold (1)	AR09.20-P-1310-03MMI
			*BA09.20-P-1001-01V
24	Raise intake manifold (1) somewhat and unclip electrical lines (10) for knock sensors on intake manifold (1)
25	Remove intake manifold (1)	Ensure that seals are seated correctly.
	Only perform operation steps 26 to 28 only when replacing the intake manifold (1)
26	Modify throttle valve actuator	Ensure that seals are seated correctly.	AR07.51-P-1401MMI
27	Modify pressure sensor downstream of throttle valve	Replace sealing ring.
			*BA09.20-P-1003-01V
28	Modify brackets for ME-SFI [ME] control unit
29	Install in the reverse order
30	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
31	Carry out an engine test run and check intake tract and fuel system for leaks

INJECTORS, INJECTION VALVES, LINES

Number	Designation			Engine 152
BA07.03-P-1001-01E	Union nut, fuel line to fuel distributor		Nm	22
BA07.03-P-1002-01E	Union nut, fuel line to high-pressure pump		Nm	22
BA07.03-P-1003-01E	Screw/bolt, fuel line service valve to cylinder head cover		Nm	9
BA07.03-P-1006-01E	Screw/bolt, fuel line clamp to charge air distribution line		Nm	6
BA07.03-P-1007-01E	Protective cap on service valve	Plastic	Nm	2
		Metal	Nm	15
BA07.03-P-1008-01E	Fuel line union nut on service valve		Nm	24
BA07.03-P-1009-01E	Screw/bolt, holding clamps for fuel line	M6	Nm	9

INTAKE MANIFOLD

Number	Designation		Engine 152
BA09.20-P-1001-01V	Screw/bolt, intake manifold to cylinder head	Nm	9
BA09.20-P-1003-01V	Screw/bolt, pressure sensor to intake manifold	Nm	4

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

Courtesy of MERCEDES-BENZ USA

REPAIR MATERIALS

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