Intake Manifold: Service and Repair

Remove, Install Intake Manifold












Removing, installing

DANGER:
- Risk of injury to skin and eyes from scalding with hot coolant which splashes out. Risk of poisoning from swallowing coolant.
- Do not open cooling system unless coolant temperature is below 90 degrees C. Open cap slowly and release the pressure. Do not pour coolant into beverage bottles.
- Wear protective gloves, protective clothing and eye protection.

1 Remove air cleaner
2 Remove ECI mains unit (N91)
3 Detach coolant vent line (7) at thermostat housing and remove cover (4)

NOTE: Collect coolant which flows out in a suitable vessel.

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

NOTE: Removal: Remove crankcase ventilation hose (2).

5 Remove switchover valves (Y32/1) and (Y32/2)
- Intake manifold M137 connection diagram
- Intake manifold M137 connection diagram (USA)

6 Release fuel pressure through service valve (1/1)

NOTE: Collect fuel.

- Tester: See Special Tools below.
- Pressure hose: See Special Tools below.

7 Unscrew fuel feed line (17/2) at fuel distributor (17)

NOTE: Collect fuel.

- Fuel feed line to fuel rail = 38 Nm

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

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

9 Remove hot film mass air flow sensor (B2/5)
10 Remove electronic accelerator actuator (M16/6) together with flap connection

NOTE: Disconnect vacuum lines (5, 6).

11 Disconnect electrical connectors

NOTE: Cylinder shutoff valve cylinders 10-12 (Y81/1), camshaft Hall sensor (B6/2) on left and (B6/3) on right, coolant temperature sensor (B11/4), intake air temperature sensor (B17), right variable camshaft timing solenoid (Y49/2) and injectors (Y62).

12 Unscrew engine wiring harness at intake manifold

NOTE: Unscrew bolts (8), (2 x). Replace mounting clip.

13 Remove engine wiring harness from firewall and place to the side
14 Remove rubber mount (9)
15 Unscrew bolts (19/1) (14 x)
- See Intake manifold below.

16 Remove complete intake manifold (19) with intake fittings (1), intake air pipes (3) and reuse the screws (19/1).

CAUTION:
- Removal: Seal intake ports. Do not disassemble the intake manifold. Do not fuel distributor (17).
- Installation: In the event of engine damage, be sure to check for and, if applicable, remove any metal chips inside the intake manifold.
17 Replace seals (19/3)

NOTE: Installation: Fix seals (19/3) in place at cylinder head using stud bolts.

18 Install in the reverse order
19 Adjust coolant to correct level

NOTE: Cooling system is bled automatically

Intake Manifold:

Special Tools: