Remove/install resonance intake manifold - AR09.20-P-1961FH

ENGINE 276.9 in MODEL 204, 207 

Illustration shows model 204.057 

Fig 1: Identifying Resonance Intake Manifold Remove/Install Components - Shows Model 204.057

Courtesy of MERCEDES-BENZ USA

Illustration shows model 204.057 

Fig 2: Identifying Resonance Intake Manifold Remove/Install Components - Shows Model 204.057

Courtesy of MERCEDES-BENZ USA

Illustration shows model 204.057 

Fig 3: Identifying Resonance Intake Manifold Remove/Install Components - Shows Model 204.057

Courtesy of MERCEDES-BENZ USA

	Remove/install
	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.	No parts of the body or limbs should be within the operating area when the components are moving.	AS00.00-Z-0011-01A
	Notes on avoiding damage through contamination and foreign objects		AH00.00-P-5000-01A
1	Switch off ignition
2	Remove front engine cover
3	Remove air filter housing	Bolt, air filter to cylinder head cover	*BA09.10-P-1001-01M
		Bolt, air filter to air intake pipe support brace	*BA09.10-P-1002-01M
4	Loosen clamp (3) for intake hose (2) on hot film MAF sensor (B25)	Replace clamp (3).
5	Pull off purge line (4) from resonance intake manifold (1)
6	Detach crankcase breather line (5) on intake hose (2) and unclip on resonance intake manifold (1)
7	Detach crankcase breather line (11) on resonance intake manifold (1)	Replace seal.
8	Disconnect electrical connection at pressure sensor downstream of throttle valve (B28/7)
9	Disconnect electrical connection on throttle valve actuator (M16/6)
10	Unclip electrical line on throttle valve actuator (M16/6)	The retaining clip for electrical line is located under the throttle valve actuator (M16/6).
11	Detach vacuum line (7) for brake booster on resonance intake manifold (1)
12	Detach vacuum line (6) to vacuum pump
13	Disconnect electrical connection on intake manifold intake air temperature sensor (B17/1)
14	Disconnect electrical connection on intake manifold selector drum switchover valve (Y773) and intake manifold resonance flap switchover valve (Y772)
15	Remove cover (1a) on resonance intake manifold (1)	Bolt, model plate cover to air intake pipe	*BA09.20-P-1008-01T
16	Remove screw/bolts (1s) for resonance intake manifold (1) on intermediate flanges (1l, 1r)	Bolt, air intake pipe to intermediate flange	*BA09.20-P-1001-01T
17	Remove resonance intake manifold (1)	Cover intermediate flange (1l, 1r) with rags. Replace seals (13).
	Only perform operation steps 18 to 23 when removing the intermediate flange (1l, 1r) for the resonance intake manifold (1)
18	Remove screw/bolts (14, 15) on right intermediate flange (1r)	Bolt, intermediate flange to cylinder head	*BA09.20-P-1002-01T
		Bolt, intermediate flange to intermediate flange	*BA09.20-P-1003-01T
19	Remove right intermediate flange (1r)	Replace seals (12).
20	Remove bracket (1) from EGR line (16)	Turn bracket (1h) to the left to remove. Ensure correct seating of the bracket (1h).
21	Remove screw/bolt (17)	Bolt, EGR line to bracket	*BA14.20-P-1005-01M
22	Remove screw/bolts on left intermediate flange (1l)	Bolt, intermediate flange to cylinder head	*BA09.20-P-1002-01T
23	Remove left intermediate flange (1l)	Cover intake ports with a rag. Replace seals (12).
24	Install in the reverse order
	Risk of accident  from vehicle starting off by itself when engine running. Risk of injury  (bruises and burns) resulting from working on the engine while it is being started or when it is running.	Secure vehicle to prevent it from starting off by itself. Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts.	AS00.00-Z-0005-01A
25	Carry out an engine test run and check resonance intake manifold (1) for leaktightness