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

ENGINE 157, 278 in MODEL 231

MODIFICATION NOTES

04.07.2016	Union nut, Fuel line to fuel distributor		BA07.03-P-1001-01E
04.07.2016	Union nut, Fuel line to high pressure pump		BA07.03-P-1002-01E

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

Courtesy of MERCEDES-BENZ USA

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

Courtesy of MERCEDES-BENZ USA

Fig 3: Intake Manifold Remove/Install Component (3 Of 3)

Courtesy of MERCEDES-BENZ USA

	Remove/install
	Risk of explosion caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel as well as risk of injury to eyes and skin caused by contact with fuel.	No fires, sparks, open flames or smoking. Pour fuels into suitable and appropriately marked containers only. Wear protective clothing when handling fuel.	AS47.00-Z-0001-01A
1	Remove ME-SFI [ME] control unit (N3/10)		AR07.08-P-7008RKB
2	Remove air filter housing (5) on the right and left
3	Remove insulation between air filter housings (5) and cylinder head covers
4	Remove bulkhead (3)
5	Remove crash plate on high-pressure pumps and remove insulation from high-pressure pumps	Remove/install high-pressure pump Only perform the operation steps required for this.	AR07.02-P-1020RKB
6	Detach vacuum line (8) for brake booster on vacuum pump and intake manifold (1)	Remove/install vacuum pump Only perform the operation steps required for this.	AR43.05-P-1320RKB
7	Detach vacuum line (7) for centrifuge on intake manifold (1)	Remove/install centrifuge Only perform the operation steps required for this.	AR01.20-P-2100RKB
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 (A9) remains on the A/C compressor (A9).	AR01.00-P-2410-02RKB
9	Remove high-pressure lines (11)	Do not bend or kink high-pressure lines (11). Leaks and damage may occur otherwise. The sealing cone for the high-pressure line (11) must be checked before assembly. The work instructions absolutely must be observed for assembly work. ↓
		Check high-pressure lines	AR07.03-P-1010-03MM
		Mount high-pressure lines.	AR07.03-P-1010-02MMB
		Check fuel high pressure circuit.	AR07.03-P-1010-04MM
		Assembly cleaner	*BR00.45-Z-1028-04A
		Union nut, fuel line to fuel distributor	*BA07.03-P-1001-01E
		Union nut, fuel line to high-pressure pump	*BA07.03-P-1002-01E
		Bolt, fuel line service valve to cylinder head cover	*BA07.03-P-1003-01E
		Bolt, right bracket for fuel line clamp to high pressure pump drive housing/cylinder head	*BA07.03-P-1004-01E
		Bolt, left bracket for high pressure line clamp to cylinder head cover/cylinder crankcase	*BA07.03-P-1005-01E
		Bolt, fuel line clamp to charge air distribution line	*BA07.03-P-1006-01E
10	Disconnect electrical line (4) on intake manifold (1)
11	Remove purge line (10) on intake manifold (1)
12	Remove boost pressure control pressure transducer vacuum line (6) (Y77/1) to vacuum pump	Bolt, pressure transducer holder to charge air distribution line	*BA09.41-P-1010-01O
13	Remove charge air ducts		AR09.41-P-8620RKB
	Risk of injury to skin and eyes suffering scalding from contact with hot coolant spray. Risk of poisoning from swallowing coolant.	Do not open cooling system unless coolant temperature is below 90 °C. Open cap slowly and release the pressure. Do not pour coolant into beverage containers. Wear protective gloves, protective clothing and safety glasses.	AS20.00-Z-0001-01A
14	Drain coolant at radiator		AR20.00-P-1142RK
	Notes on coolant		AH20.00-N-2080-01A
15	Disconnect bleed line (20) for charge air cooler (2) at connecting point
16	Remove clamp for the low temperature line (20) on bracket for ABC pump or guide pulley	Bolt, low temperature line clamp to bracket	*BA09.41-P-1004-01O
17	Remove poly-V belt		AR13.20-P-0001RKB
18	Remove ABC pump with bracket on timing case cover and place with attached lines to one side	Model 231 with engine 157, 278 with code 487 (Active Body Control (ABC))	AR32.50-P-0030RK
		Bolt, guide pulley carrier/ABC pump to timing case cover/coolant pump	*BA13.25-P-1003-01Y
19	Remove coolant return line (21) on oil filter housing	Bolt, coolant line to timing case cover/oil filter housing	*BA09.41-P-1006-01O
20	Remove coolant return line (21) on coolant hose (22)
21	Remove coolant return line (23) on timing case cover	Bolt, coolant line to timing case cover/oil filter housing	*BA09.41-P-1006-01O
22	Remove bracket (28) for feed line (24) on timing case cover	Bolt, feed line to timing case cover	*BA09.41-P-1005-01O
23	Remove feed line (24) on coolant hose (27)
24	Remove bracket (26) for feed line (24) on timing case cover	Bolt, feed line to timing case cover	*BA09.41-P-1005-01O
25	Remove hose fitting (29) for vent line (20) from timing case cover	To do this remove screw/bolt for hose fitting (29) for bleed line on timing case cover and pull hose fitting (29) out of the timing case cover. Replace sealing ring on oil dipstick guide tube (29). Bolt, bleed lines hose fitting to timing case cover	*BA09.41-P-1007-01O
26	Remove screw/bolts (30) for intake manifold (1) on cylinder heads	Bolt, charge air distribution line to cylinder head	*BA09.41-P-1011-01O
27	Lift intake manifold (1)
28	Disconnect electrical line (9) on front knock sensors
29	Unclip electrical line (9) for front knock sensors on intake manifold (1)
30	Remove intake manifold (1) upwards
31	Remove detachable parts from intake manifold (1)	To do this remove screw/bolts (31) for charge air cooler (2) on intake manifold (1) and loosen clamp on throttle valve actuator. Bolt, charge air cooler to charge air distribution line	*BA09.41-P-1001-01O
32	Install in the reverse order
	Check
	Risk of injury to skin and eyes suffering scalding from contact with hot coolant spray. Risk of poisoning from swallowing coolant.	Do not open cooling system unless coolant temperature is below 90 °C. Open cap slowly and release the pressure. Do not pour coolant into beverage containers. Wear protective gloves, protective clothing and safety glasses.	AS20.00-Z-0001-01A
3	Check cooling system for leaktightness		AR20.00-P-1010RK
	Notes on coolant		AH20.00-N-2080-01A
34	Read out fault memory with STAR DIAGNOSIS and clear if necessary
	Connect STAR DIAGNOSIS and read out fault memory		AD00.00-P-2000-04A
	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
35	Carry out an engine test run and check intake tract and fuel system for leaktightness

INJECTION NOZZLES, INJECTION VALVES, LINES

Number	Designation				Engine 157	Engine 278
BA07.03-P-1001-01E	Union nut, fuel line to fuel distributor	In case of reusability	Nm		22	22
		For new lines	Stage 1	Nm	15	15
		For new lines	Stage 2	∠°	90	90

INJECTION NOZZLES, INJECTION VALVES, LINES

Number	Designation				Engine 157	Engine 278
BA07.03-P-1002-01E	Union nut, fuel line to high pressure pump	In case of reusability		Nm	22	22
		For new lines	Stage 1	Nm	15	15
		For new lines	Stage 2	∠°	90	90

INJECTION NOZZLES, INJECTION VALVES, LINES

Number	Designation		Engine 157	Engine 278
BA07.03-P-1003-01E	Bolt, fuel line service valve to cylinder head cover	Nm	9	9

INJECTION NOZZLES, INJECTION VALVES, LINES

Number	Designation		Engine 157	Engine 278
BA07.03-P-1004-01E	Bolt, right bracket for fuel line clamp to high pressure pump drive housing/cylinder head	Nm	14	14

INJECTION NOZZLES, INJECTION VALVES, LINES

Number	Designation		Engine 157	Engine 278
BA07.03-P-1005-01E	Bolt, left bracket for high pressure line clamp to cylinder head cover/cylinder crankcase	Nm	9	9

INJECTION NOZZLES, INJECTION VALVES, LINES

Number	Designation		Engine 157	Engine 278
BA07.03-P-1006-01E	Bolt, fuel line clamp to charge air distribution line	Nm	5	5