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Home >> Mercedes Benz >> 2014 >> ML350 Base >> Repair and Diagnosis >> Engine Mechanical >> Blowers, Superchargers & Turbochargers >> Air Intake, Turbocharging - 166 Chassis >> Testing & Repair >> Remove/install intake manifold - AR09.20-P-1310MLJ

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

ENGINES 157, 278 in MODEL 166 

Shown on engine 278 

Fig 1: Identifying Intake Manifold Remove/Install Components - Shown On Engine 278 (1 Of 4)
G09981812Courtesy of MERCEDES-BENZ USA
Fig 2: Identifying Intake Manifold Remove/Install Components - Shown On Engine 278 (2 Of 4)
G09981813Courtesy of MERCEDES-BENZ USA
Fig 3: Identifying Intake Manifold Remove/Install Components - Shown On Engine 278 (3 Of 4)
G09981814Courtesy of MERCEDES-BENZ USA
Fig 4: Identifying Intake Manifold Remove/Install Components - Shown On Engine 278 (4 Of 4)
G09981815Courtesy of MERCEDES-BENZ USA
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
    NOTES The ground line on battery must always  be detached before beginning work on fuel system. Pressure will be built up in the fuel system otherwise upon opening a vehicle door or the trunk lid.  
1 Remove ME-SFI [ME] control unit (N3/10)   AR07.08-P-7008MLJ
2 Remove both air filter housings (5)    
3 Remove insulation between air filter housings (5) and cylinder head cover    
4 Remove left and right engine compartment partition wall (3) INSTALLATION IMPORTANT Ensure correct seating of the partition wall (3).  
5 Remove crash plate on high-pressure pumps and remove insulation from high-pressure pumps   AR07.02-P-1020MLJ
6 Detach vacuum line (8) for brake booster on vacuum pump and intake manifold (1)   AR43.05-P-1320MLJ
7 Detach vacuum line (7) for centrifuge on intake manifold (1)   AR01.20-P-2100MLJ
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-2410-02GQ
9 Reduce fuel pressure through service valve   AR07.03-P-1460-01VA
AR07.03-P-1460-02MM
10 Remove high-pressure lines (11) NOTES Do not bend or kink high-pressure lines (11). This prevents leaks and damage.
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 
11 Disconnect electrical line (4) on intake manifold (1)    
12 Detach purge line (10) on intake manifold (1)    
13 Remove expansion reservoir (32) and lay down to side    
14 Detach vacuum line (6) for boost pressure control pressure transducer (Y77/1) on vacuum pump    
15 Detach boost pressure control pressure transducer (Y77/1) with bracket on intake manifold (1) and lay down to the front TORQUE SPECIFICATION *BA09.41-P-1010-01O 
16 Detach oil lines at oil filter housing Engine 157  
17 Remove charge air ducts   AR09.41-P-8620MLJ 
18 Drain coolant at radiator   AR20.00-P-1142GQ
NOTES Notes on coolant   AH20.00-N-2080-01A
19 Disconnect bleed line (20) for charge air cooler (2) at connecting point    
20 Detach clamp for bleed line (20) on Active Roll Stabilization hydraulic pump carrier or guide pulley TORQUE SPECIFICATION *BA09.41-P-1004-01O 
21 Remove poly-V belt   AR13.20-P-0001MLJ
22.1 Detach Active Roll Stabilization hydraulic pump with bracket on timing case cover and place to one side with attached lines Vehicles with code (468) ACTIVE CURVE SYSTEM AR32.34-P-0030MLJ
TORQUE SPECIFICATION *BA13.25-P-1003-01Y 
22.2 Remove guide pulley with bracket on timing case cover Vehicles without code (468) ACTIVE CURVE SYSTEM  
TORQUE SPECIFICATION *BA13.25-P-1003-01Y 
23 Detach coolant return line (21) on oil filter housing TORQUE SPECIFICATION *BA09.41-P-1006-01O 
24 Detach coolant return line (21) on coolant hose (22)    
25 Detach coolant return line (23) on timing case cover TORQUE SPECIFICATION *BA09.41-P-1006-01O 
26 Detach lower bracket (28) for coolant feed line (24) on timing case cover TORQUE SPECIFICATION *BA09.41-P-1005-01O 
27 Detach coolant feed line (24) on coolant hose (27)    
28 Detach upper bracket (26) for coolant feed line (24) on timing case cover TORQUE SPECIFICATION *BA09.41-P-1005-01O 
29 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 
30 Remove bolts (30) for intake manifold (1) on cylinder heads TORQUE SPECIFICATION *BA09.41-P-1011-01O 
31 Lift intake manifold (1)    
32 Disconnect electrical connection (9) at front knock sensors    
33 Unclip electrical connection (9) for front knock sensors on intake manifold (1)    
34 Remove intake manifold (1) upwards    
35 Modify detachable parts from intake manifold (1) IMPORTANT If necessary
IMPORTANT To do this remove screw/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 
36 Install in the reverse order    
37 Inspect cooling system for leaks   AR20.00-P-1010GQ
38 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
39 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 Screw/bolt, charge air cooler to charge air distribution line Nm 9 9
BA09.41-P-1004-01O Screw/bolt, low temperature line clamp to bracket Nm 9 9
BA09.41-P-1005-01O Screw/bolt, feed line to timing case cover Nm 9 9
BA09.41-P-1006-01O Screw/bolt, coolant line to timing case cover/oil filter housing Nm 9 9
BA09.41-P-1007-01O Screw/bolt, bleed lines hose fitting to timing case cover Nm 9 9
BA09.41-P-1010-01O Screw/bolt, pressure transducer holder to charge air distribution line Nm 5 5
BA09.41-P-1011-01O Screw/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 Screw/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 Screw/bolt, fuel line service valve to cylinder head cover Nm 9 9
BA07.03-P-1004-01E Screw/bolt, right bracket for fuel line clamp to high pressure pump drive housing/cylinder head Nm 14 14
BA07.03-P-1005-01E Screw/bolt, left bracket for high pressure line clamp to cylinder head cover/cylinder crankcase Nm 9 9
BA07.03-P-1006-01E Screw/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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