Intake manifold (Mercedes-Benz Vito W638)

Removal

1. Remove the mixing chamber with the exhaust gas recirculation valve 9 from the intake manifold 8 (see figure 5.8).

Figure 5.8. Intake manifold:
2. Cooling module of the exhaust gas recirculation system,
3. Cylinder head,
4. Fuel distributor,
6. Oil level indicator guide tube,
7. Bracket,
8. Intake manifold,
9. Mixing chamber with exhaust gas recirculation valve,
10, 16. Gasket,
11. Oil filler neck.

2. Drain the coolant, remove the front cross member, radiator grille and disconnect the air duct from the bottom of the air cleaner.

3. Loosen the bolt securing the fuel lines to the EGR cooling module 2.

4. Unscrew the bolts securing the cooling module 2 of the exhaust gas recirculation system to the cylinder head 3.

5. Loosen the banjo bolts securing the drain line to the fuel distributor 4. Replace the gasket.

6. Unscrew the bolt securing the oil level indicator guide pipe 6 to the bracket 7.

7. Unscrew the bolt securing the oil filler neck 11 to the bracket 7.

8. Unscrew the bolt securing bracket 7 to intake manifold 8.

9. Unscrew the bracket mounting bolts 7 from the top and bottom.

10. Unscrew the bolts securing bracket 7 to the cylinder block.

11. Unhook and disconnect the fuel lines from the intake manifold 8.

12. Unscrew the bolts securing the intake manifold 8 to the cylinder head 3.

13. Remove the intake manifold 8. Wipe the sealing surfaces.