Remove/install intake manifold

AR09.20-P-1310L

Remove/install intake manifold

16.12.08

 

Remove/install

 Danger!

Risk of injury to skin and eyes caused by scalding from contact with hot coolant spray. Risk of poisoning caused by 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



Notes on coolant

All engines.

AH20.00-N-2080-01A

1

Remove air filter

AR09.10-P-1050L

2

Remove ECI power supply unit (N91)

3

Close off coolant venting line (7) on thermostat housing and remove cover (4)

 Collect escaping coolant in a suitable container.

4

Disconnect hose (2) for crankcase ventilation system at couplings (A) and (B)

 Removal: Remove hose (2) for crankcase ventilation system.

5

Remove switchover valves (Y32/1) and (Y32/2)

Intake manifold connection diagram M137

AR09.20-P-1310-01L

Intake manifold connection diagram M137 

AR09.20-P-1310-01LA

6

Release fuel pressure through service valve (1/1)

 Collect fuel.



*103589002100



*119589046300

7

Unscrew fuel feed line (17/2) on fuel distributor (17)

 Collect fuel.



*BA07.52-P-1001-01A

8

Unscrew mounting clamp for fuel feed line (17/2) at left cylinder head cover

 Removal: It is not permissible to bend fuel feed line out of the way. There is a risk of crack formation at the fuel rail, and also at the fuel feed line.

9

Remove hot film mass air flow sensor (B2/5)

AR07.07-P-1453L

10

Remove electronic accelerator actuator (M16/6) with flap fitting

 Close off vacuum lines (5, 6).

AR30.20-P-1262L

11

Disconnect electrical connectors

 Cylinder shutoff valve for cylinders 10-12 (Y81/1), camshaft Hall sensor (B6/2) on the left and (B6/3) right, coolant temperature sensor (B11/4), temperature sensor for intake air (B17), camshaft timing solenoid (Y49/2) on the right and injection valves (Y62).

12

Unscrew engine wiring harness at intake manifold

 Remove bolts (8), (2 each) Replace mounting clips.

13

Remove engine wiring harness from bulkhead and place to one side

14

Remove rubber bushing (9)

15

Remove bolts (19/1) (14 pieces)



*BA09.20-P-1001-01G

16

Remove intake manifold (19) complete with intake connection (1), the intake air pipes (3) and the fuel distributor (17)

 Removal: Close off intake ports. The intake manifold must not be disassembled. The bolts (19/1) may only be used once.

 Installation: In the case of engine damage the intake manifold must be checked for metal shavings and cleaned if necessary.

17

Replace gaskets (19/3).

 Installation: Fix seals (19/3) on cylinder head using studs.

18

Install in the reverse order

19

Adjust coolant to correct level

 Cooling system bleeds itself automatically.

Number

Designation

Engine
137

BA07.52-P-1001-01A

Fuel feed line to fuel distributor

Nm

38

Number

Designation

Engine 137

BA09.20-P-1001-01G

Bolt from intake manifold to cylinder head

Stage 1

M6

Nm

8

M8

Nm

20

Stage 2

M6

Nm

8

Stage 3

M6

 °

90