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

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ENGINE 157, 278 in MODEL 212, 218 

ENGINE 278 in MODEL 207 

Shown on model 218.373 without code (139) Measures for engine cooling M157/M278) 

Fig 1: Intake Manifold Remove/Install Components - Shown On Model 218.373 (1 Of 3)
G09974846Courtesy of MERCEDES-BENZ USA

Shown on model 218.373 without code (139) Measures for engine cooling M157/M278) 

Fig 2: Intake Manifold Remove/Install Components - Shown On Model 218.373 (2 Of 3)
G09974847Courtesy of MERCEDES-BENZ USA

Shown on model 218.373 without code (139) Measures for engine cooling M157/M278) 

Fig 3: Intake Manifold Remove/Install Components - Shown On Model 218.373 (3 Of 3)
G09974848Courtesy of MERCEDES-BENZ USA
REMOVINGINSTALLING Remove/install     
DANGER 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 General information on work on gasoline direct injection system   AH07.00-P-2000-01A
1 Detach ground line from battery   AR54.10-P-0005EW
2 Remove ME-SFI [ME] control unit (N3/10)   AR07.08-P-7008ELB
3 Remove low-temperature circuit coolant expansion reservoir Vehicles with code 139 (Measures for engine cooling M157/M278)  
      AR09.41-P-0001ELB
4 Remove upper section of coolant line to the low-temperature circuit coolant expansion reservoir Vehicles with code 139 (Measures for engine cooling M157/M278)  
      AR20.20-P-7442ELB
5 Remove both air filter housings (5)    
6 Remove insulation between air filter housings (5) and cylinder head cover    
7 Remove center section of the bulkhead (3) INSTALLATION IMPORTANT Ensure correct seating of the center section of the bulkhead (3).  
8 Remove crash plate on high-pressure pumps and remove insulation from high-pressure pumps   AR07.02-P-1020ELB
9 Detach vacuum line (8) for brake booster on vacuum pump and intake manifold (1)   AR43.05-P-1320ELB
10 Detach vacuum line (7) for centrifuge on intake manifold (1)   AR01.20-P-2100ELB
11 Disconnect engine wiring harness on intake manifold (1) and cylinder head covers and lay down to the rear   AR01.00-P-2410-02ELB
    IMPORTANT The electrical line for actuation of the A/C compressor remains on the A/C compressor.  
12 Remove high-pressure lines (11) NOTES
Do not bend or kink high-pressure lines (11). This prevents leaks and damage.
The work instructions absolutely must be observed for assembly work
↓
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 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 Union nut, fuel line to fuel distributor *BA07.03-P-1001-01E 
    TORQUE SPECIFICATION Union nut, fuel line to high-pressure pump *BA07.03-P-1002-01E 
    TORQUE SPECIFICATION Bolt, fuel line service valve to cylinder head cover *BA07.03-P-1003-01E 
    TORQUE SPECIFICATION Bolt, right bracket for fuel line clamp to high pressure pump drive housing/cylinder head *BA07.03-P-1004-01E 
    TORQUE SPECIFICATION Bolt, left bracket for high pressure line clamp to cylinder head cover/cylinder crankcase *BA07.03-P-1005-01E 
    TORQUE SPECIFICATION Bolt, fuel line clamp to charge air distribution line *BA07.03-P-1006-01E 
13 Disconnect electrical line (4) on intake manifold (1)    
14 Detach purge line (10) on intake manifold (1)    
15 Detach vacuum line (6) for boost pressure control pressure transducer (Y77/1) on vacuum pump    
16 Detach boost pressure control pressure transducer (Y77/1) with bracket on intake manifold (1) and lay down to the front TORQUE SPECIFICATION Bolt, pressure transducer holder to charge air distribution line *BA09.41-P-1010-01O 
17 Remove charge air ducts   AR09.41-P-8620ELB
18 Drain coolant Vehicles without code (139) Measures for engine cooling M157/M278  
NOTES Notes on coolant   AH20.00-N-2080-01A
    MODEL 207 AR20.00-P-1142FH
    MODEL 212, 218 AR20.00-P-1142EL
19 Disconnect bleed line (20) for charge air cooler (2) at connecting point Vehicles without code (139) Measures for engine cooling M157/M278  
20 Detach clamp for bleed line (20) on ABC pump carrier or guide pulley TORQUE SPECIFICATION Bolt, low temperature line clamp to bracket *BA09.41-P-1004-01O 
21 Remove poly-V belt   AR13.20-P-0001ELB
22.1 Detach ABC pump with bracket on timing case cover and place with attached lines to one side Vehicles with code (487) Active Body Control (ABC)  
    TORQUE SPECIFICATION Bolt, guide pulley carrier/ABC pump to timing case cover/coolant pump *BA13.25-P-1003-01Y 
22.2 Remove guide pulley with bracket on timing case cover Vehicles without code (487) Active Body Control (ABC)  
    TORQUE SPECIFICATION Bolt, guide pulley carrier/ABC pump to timing case cover/coolant pump *BA13.25-P-1003-01Y 
23 Detach coolant return line (21) on oil filter housing TORQUE SPECIFICATION Bolt, coolant line to timing case cover/oil filter housing *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 Bolt, coolant line to timing case cover/oil filter housing *BA09.41-P-1006-01O 
26 Detach clamp for coolant feed line (24) on the front cover Vehicles with code (M005) 4MATIC  
27 Detach lower bracket (28) for coolant feed line (24) on timing case cover TORQUE SPECIFICATION Bolt, feed line to timing case cover *BA09.41-P-1005-01O 
28 Detach coolant feed line (24) on coolant hose (27)    
29 Detach upper bracket (26) for coolant feed line (24) on timing case cover TORQUE SPECIFICATION Bolt, feed line to timing case cover *BA09.41-P-1005-01O 
30 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 INSTALLATION IMPORTANT Replace sealing ring on oil dipstick guide tube (29).  
    TORQUE SPECIFICATION Bolt, bleed lines hose fitting to timing case cover *BA09.41-P-1007-01O 
31 Remove screw/bolts (30) for intake manifold (1) on cylinder heads TORQUE SPECIFICATION Bolt, charge air distribution line to cylinder head *BA09.41-P-1011-01O 
32 Lift intake manifold (1)    
33 Disconnect electrical line (9) on front knock sensors    
34 Unclip electrical line (9) for front knock sensors on intake manifold (1)    
35 Remove intake manifold (1) upwards    
36 Modify detachable parts from intake manifold (1) When replacing
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 Bolt, charge air cooler to charge air distribution line *BA09.41-P-1001-01O 
37 Install in the reverse order    
INSPECT Check     
38.1 Check cooling system for leaktightness Vehicles without code (139) Measures for engine cooling M157/M278  
    MODEL 207 AR20.00-P-1010FH
    MODEL 212, 218 AR20.00-P-1010EL
38.2 Check cooling system for low-temperature circuit for leaktightness Vehicles with code 139 (Measures for engine cooling M157/M278)  
    MODEL 207 AR20.00-P-1010FH
    MODEL 212, 218
IMPORTANT Screw tester cap onto low-temperature circuit coolant expansion reservoir and apply the test pressure to the cooling system of the low-temperature circuit.		 AR20.00-P-1010EL
39 Read out fault memory with STAR DIAGNOSIS and delete if necessary    
REFER TO SELF-DIAGNOSTIC SYSTEMS Connect STAR DIAGNOSIS and read out fault memory   AD00.00-P-2000-04A
DANGER 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
40 Carry out an engine test run and check intake tract and fuel system for leaktightness    
CHARGE AIR PIPE/CHARGE AIR COOLING

Number Designation ENGINE 157 ENGINE 278
BA09.41-P-1010-01O Bolt, pressure transducer holder to charge air distribution line Nm 5 5
CHARGE AIR PIPE/CHARGE AIR COOLING

Number Designation ENGINE 157 ENGINE 278
BA09.41-P-1001-01O Bolt, charge air cooler to charge air distribution line Nm 9 9
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-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-1002-01E Union nut, fuel line to high-pressure pump Nm 22 22
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
CHARGE AIR PIPE/CHARGE AIR COOLING

Number Designation ENGINE 157 ENGINE 278
BA09.41-P-1004-01O Bolt, low temperature line clamp to bracket Nm 9 9
CHARGE AIR PIPE/CHARGE AIR COOLING

Number Designation ENGINE 157 ENGINE 278
BA09.41-P-1007-01O Bolt, bleed lines hose fitting to timing case cover Nm 9 9
CHARGE AIR PIPE/CHARGE AIR COOLING

Number Designation ENGINE 157 ENGINE 278
BA09.41-P-1005-01O Bolt, feed line to timing case cover Nm 9 9
CHARGE AIR PIPE/CHARGE AIR COOLING

Number Designation ENGINE 157 ENGINE 278
BA09.41-P-1006-01O Bolt, coolant line to timing case cover/oil filter housing 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
CHARGE AIR PIPE/CHARGE AIR COOLING

Number Designation ENGINE 157 ENGINE 278
BA09.41-P-1011-01O 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 Bolt, guide pulley carrier/ABC pump to timing case cover/coolant pump Nm 20 20
INJECTION NOZZLES, INJECTION VALVES, LINES

Number Designation ENGINE 157 ENGINE 278
BA07.03-P-1001-01E Union nut, fuel line to fuel distributor Nm 22 22
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