Intake manifold (Mercedes-Benz Vito W638)

Removal

1. Disconnect the negative cable from the battery.

2. Remove the radiator 1 (see figure 3.9).

Figure 3.9. Intake manifold:
1. Radiator,
2. Air flow sensor,
3. Sapun,
4. Accelerator cable,
5. Air intake pipe,
6. Throttle body,
7. Air temperature sensor,
8. Cooling system pipes,
9. Vacuum tube,
10. Check valve,
11. Generator drive belt tensioner,
12. Generator drive belt,
13. Generator,
14, 15, 16. Bolts,
17. Intake manifold,
18. Cylinder head,
19. Guide tube of oil level indicator.

3. Loosen the air flow sensor 2 mounting clamps.

4. Disconnect the connector from breather 3.

5. Disconnect the accelerator cable 4.

6. Disconnect the delivery tubes from the injectors.

7. Disconnect the air inlet pipe 5.

8. Disconnect the wires from the spark plugs.

9. Disconnect the connector from the variable geometry intake manifold control valve 17.

10. Disconnect the connector from the throttle body 6.

11. Disconnect the connector from the air temperature sensor 7.

12. Disconnect the cooling system pipes 8 from the throttle body 6.

13. Disconnect the injector connectors from the clips.

14. Plug the fuel supply and drain lines.

15. Disconnect the vacuum pipe from the throttle body.

16. Disconnect vacuum tube 9 from test valve 10.

17. Disconnect the fuel tank vent pipe.

18. Remove the generator drive belt tensioner 11.

(Original source of information: mercedesman)

19. Unscrew the bolts securing the generator 13 to the bracket.

20. Remove the attachment flanges on the intake manifold 17.

21. Disconnect the tube from the crankcase ventilation valve in the intake manifold 17.

22. Unscrew bolts 14 securing the intake manifold bracket to the cylinder head 18.

23. Remove bolts 15 securing test valve 10 from the secondary air supply pump on intake manifold 17 and remove test valve 10.

24. Unscrew bolts 16 securing the intake manifold 17 to the cylinder head 18.

25. Remove the oil level indicator guide tube 19.

26. Remove the intake manifold 17.