Remove/install intake manifold

AR09.20-P-1310RT

Remove/install intake manifold

6.12.05

 

Remove/install

 Danger!

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 fire, sparks, open flames or smoking.
Only pour fuels into suitable and appropriately marked containers.

Wear protective clothing when handling fuel.

AS47.00-Z-0001-01A

 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.

When moving components, ensure that no body parts or limbs are within operating range of moving parts.

AS00.00-Z-0011-01A

1

Switch ignition off and remove ignition key (transmitter key).

 On vehicles with code 889 Keyless Go: Press Keyless Go start/stop button repeatedly until the ignition is switched off. Remove transmitter key from vehicle and store it in a location beyond its transmission range (at least 2 m).

2

Open engine hood and raise to vertical position

AR88.40-P-1000RT

3

Remove air filter housing

AR09.10-P-1150RT

4

Remove hot film mass air flow sensor with air intake pipe

AR07.07-P-1454RT

5

Dismount fuel line (3) from fuel distributor



*BA07.52-P-1001-01A

6

Removing fuel rail with injection valves

AR07.03-P-1451RT



*BA07.52-P-1002-01A

7

Remove vacuum lines from intake manifold (1) and variable intake manifold switchover valve (Y22/6)

 Installation: Observe intake manifold connection diagram.

AR09.20-P-1310-01GZ

8

Disconnect electrical connector at variable intake manifold switchover valve (Y22/6)

9

Screw down union nut (5) on line to exhaust gas recirculation valve (4)

 Counterhold connection fitting when unscrewing.

10

Remove combination valves (6)

11

Remove intake manifold (1) bolts on cylinder head



*BA09.20-P-1001-01D

12

Remove intake manifold (1) upwards

 Plug intake ducts.

 The intake manifold must not be disassembled.

 Installation: Replace seals (2). When mounting observe correct seating of bore for combination valve (see arrow).

 Installation: Use centering pin to achieve exact bottoming of intake manifold as well as centering of seals (2) .

Set of dowel bolts

*112589026200

13

Install in the reverse order

 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 a running engine

Secure vehicle to prevent it from moving by itself.
Wear closed and snug-fitting work clothes.
Do not grasp hot or rotating parts.

AS00.00-Z-0005-01A

14

Carry out engine test run and check intake manifold (1) for leaks

 In the event of a leak, determine and eliminate cause, otherwise malfunctions and serious environmental pollution may occur.

Number

Designation

Engines
113.940/941/
942/943/944/
945/946/948/
960/961/962/
963/964/965/
966/967/968/
969/971/980/
981/982/984/
986/988

BA07.52-P-1001-01A

Disconnect fuel feed line at fuel rail

Nm

38

BA07.52-P-1002-01A

Bolt, fuel rail to intake manifold

Nm

10

Number

Designation

Engines
112, 113

BA09.20-P-1001-01D

Bolt, intake manifold to cylinder head

M8

Nm

20