Contents: Removal ↡ Installation ↡
Cars with diesel engines.
Removal
1. Disconnect the air intake hose 1 (see illustration).
2. Remove mixer 2 by disconnecting low pressure hose 3 from the EGR valve, boost air hose 4 from the mixer, EGR system line 5 from the bottom of the mixer (see illustration 9.1).
3. Unscrew the four mounting bolts and disconnect the mixer from the inlet module.
4. Unscrew the mounting bolts (see arrows in the illustration) and disconnect fuel filter 1 from inlet module 2 without removing the hoses from it.
5. Remove the low pressure hose of the brake booster from the fitting on the right side, when viewed in the direction of travel, by squeezing the side leashes and releasing the hose from the mount on the manifold.
6. Disconnect the low pressure hose from the boost air pressure sensor.
7. Cars manufactured since 9/00. Unscrew the mounting bolts 2 of the oil separator 1, mark the attachment points of all hoses, disconnect them and remove the oil separator (see illustration).
8. Unscrew the bolt securing the oil filler pipe to the intake module.
9. Unscrew the three bolts securing the heat shield.
10. Remove the intake module to cylinder head mounting bolts, removing the engine lifting eyes and marking the mounting position of the dipstick guide and all wiring harness holders and clamps.
11. Remove the air intake tube from the intake module by first moving the locking lever 1 to the right, if looking in the direction of travel, and then pressing it down (see arrows in the illustration).
12. Disconnect the intake module.
Installation
13. Place eight new profile sealing gaskets on the cylinder head.
14. Install the intake module, connect the air intake tube to it and secure it with the lever.
15. Secure the intake module to the cylinder head with bolts to a tightening torque of 14 Nm.
At the same time, install the guide tube of the engine oil level indicator by screwing in the bolt that secures it.
16. Reinstall all wire harness holders and clamps in their original locations.
17. Secure the heat shield with three bolts.
18. Install and secure the oil filler pipe to the intake module, tightening the mounting bolts to 9 Nm.
19. Cars produced since 9/00. Install the oil separator, connect the hoses, I following the marks made before removal and the reference marks (see illustration 9.7).
20. Connect the low pressure hose to the boost air pressure sensor.
21. Secure the low pressure hose of the vacuum booster to the holders on the intake manifold and connect it to the fitting on the manifold.
22. Fasten the fuel filter to the intake module with bolts.
23. Install the air mixer, after cleaning the sealing surfaces of the inlet module and mixer, and installing a new rubber seal.
24. Secure the mixer with bolts to the inlet module, tightening them to 9 Nm.
25. Connect the air recirculation system pipe, tightening it to 9 Nm.
Publication taken from an online resource [MercedesMan.ru]
26. Install the boost air hose and secure it with a clamp.
Attention! Before doing this, thoroughly clean the hose landing branch, because over time the hose may come off during operation.
27. Connect the low pressure hose to the recirculation valve.
28. Connect the air intake hose.