Remove/Install Intake Manifold - AR09.20-P-1310MLJ

Engine 157, 278 in model 166 

Engine 157, 278 in model 292 

Shown on engine 278 

Courtesy of MERCEDES-BENZ USA

Courtesy of MERCEDES-BENZ USA

Courtesy of MERCEDES-BENZ USA

Fig 1: Intake Manifold Components Location - Engine 278 In Model 166

Courtesy of MERCEDES-BENZ USA

	General information on work on gasoline direct injection system		AH07.00-P-2000-01A
	Remove/install
1	Detach ground line from battery		AR54.10-P-0005GZ
2	Remove ME-SFI [ME] control unit (N3/10)		AR07.08-P-7008MLJ
3	Remove both air filter housings (5)
4	Remove insulation between air filter housings (5) and cylinder head cover
5	Remove left and right engine compartment partition wall (3)	Ensure correct seating of the partition wall (3).
6	Remove crash plate on high-pressure pumps and remove insulation from high-pressure pumps		AR07.02-P-1020MLJ
7	Detach vacuum line (8) for brake booster on vacuum pump and intake manifold (1)		AR43.05-P-1320MLJ
8	Detach vacuum line (7) for centrifuge on intake manifold (1)		AR01.20-P-2100MLJ
9	Disconnect engine wiring harness on intake manifold (1) and cylinder head covers and lay down to the rear		AR01.00-P-2410-02MLJ
		The electrical line for actuation of the A/C compressor remains on the A/C compressor.
10	Relieve fuel pressure over diagnostic socket		AR07.03-P-1460-01VA
11	Relieve fuel pressure in fuel system high-pressure circuit		AR07.03-P-1460-02MM
12	Remove high-pressure lines (11)	Do not bend or kink high-pressure lines (11). Leaks and damage can occur otherwise for possible reuse (after successfully passing checking) of the high-pressure line.
		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
		Assembly cleaner	*BR00.45-Z-1028-04A
		The sealing cone for the high-pressure line (11) must be checked before assembly. ↓ A leak test on the fuel high-pressure circuit must be carried out after assembly
		Check fuel high pressure circuit.	AR07.03-P-1010-04MM
		Check high-pressure lines	AR07.03-P-1010-03MM
		Mount high-pressure lines.	AR07.03-P-1010-02MMB
13	Disconnect electrical line (4) on intake manifold (1)
14	Detach purge line (10) on intake manifold (1)
15	Remove expansion reservoir (32) and lay down to side
16	Detach vacuum line (6) for boost pressure control pressure transducer (Y77/1) on vacuum pump
17	Detach boost pressure control pressure transducer (Y77/1) with bracket on intake manifold (1) and lay down to the front	Bolt, pressure transducer holder to charge air distribution line	*BA09.41-P-1010-01O
18	Detach oil lines at oil filter housing	Engine 157 in model 166 Engine 157 in model 292
19	Remove charge air line		AR09.41-P-8620MLJ
20	Drain coolant at radiator		AR20.00-P-1142GQ
21	Disconnect bleed line (20) for charge air cooled (2) at connecting point
22	Detach clamp for bleed line (20) on Active Roll Stabilization hydraulic pump carrier or guide pulley	Bolt, low temperature line clamp to bracket	*BA09.41-P-1004-01O
23	Remove poly-V belt		AR13.22-P-1202MLJ
24.1	Detach Active Roll Stabilization hydraulic pump carrier with bracket on timing case cove and place with attached lines to one side	Engine 157, 278 in model 166 with code 468 (ACTIVE CURVE SYSTEM) Engine 157, 278 in model 292 with code 468 (ACTIVE CURVE SYSTEM)
			AR32.34-P-0030MLJ
		Bolt, guide pulley carrier/ABC pump to timing case cover/coolant pump	*BA13.25-P-1003-01Y
24.2	Remove guide pulley with bracket on timing case cover	Engine 157, 278 in model 166 except code 468 (ACTIVE CURVE SYSTEM) Engine 157, 278 in model 292 except code 468 (ACTIVE CURVE SYSTEM)
		Bolt, guide pulley carrier/ABC pump to timing case cover/coolant pump	*BA13.25-P-1003-01Y
25	Detach coolant return line (21) from oil filter housing	Bolt, coolant line to timing case cover/oil filter housing	*BA09.41-P-1006-01O
26	Detach coolant return line (21) on coolant hose (22)
27	Detach coolant return line (23) on timing case cover	Bolt, coolant line to timing case cover/oil filter housing	*BA09.41-P-1006-01O
28	Detach lower bracket (28) for coolant feed line (24) on timing case cover	Bolt, feed line to timing case cover	*BA09.41-P-1005-01O
29	Detach coolant feed line (24) from coolant hose (27)
30	Detach upper bracket (26) for coolant feed line (24) on timing case cover	Bolt, feed line to timing case cover	*BA09.41-P-1005-01O
31	Remove screw/bolt for hose fitting (29) for bleed line (20) 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
32	Remove screw/bolts (30) for intake manifold (1) on cylinder heads	Bolt, charge air distribution line to cylinder head	*BA09.41-P-1011-01O
33	Lift intake manifold (1)
34	Disconnect electrical connection (9) on front knock sensors
35	Unclip electrical connection (9) for front knock sensors on intake manifold (1)
36	Remove intake manifold (1) upwards
37	Modify detachable parts from intake manifold (1)	When replacing 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
38	Install in the reverse order
	Check
39	Check engine cooling system for leak tightness		AR20.00-P-1010GQ
40	Read out fault memory using the diagnostic system and clear if necessary
			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
41	Carry out an engine test run and check leaktightness from intake air system and fuel system