E-Class (W212) 2010 - 2016: E 350, E 550
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Starting my intake manifold replacement. Wish me luck guys!

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Old Oct 28, 2024 | 02:09 PM
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Starting my intake manifold replacement. Wish me luck guys!

So i've got the infamous DTC 0521 / P2004 "The charge movement flap (cylinder bank 1) has a malfunction" along with multiple misfires, rough idling, poor acceleration... Got a Pierburg shipping from FCP. Time to open her up. Hope i don't screw up.. Anything else I should do while I'm at it? Tips??


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Old Oct 28, 2024 | 04:32 PM
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Good luck man, I`m always in between for this job, part of me says you can do it, part of me like naaahh, I have a 272 and 273 engines at the moment both are about 140K miles and ok at the moment but I know sooner or later I will have to do it.
I saw a very detailed video a few weeks ago that boosted my confidence.
Only tip I can say is the new holes on the intake manifold will be self tapping, everybody says you need to be careful at that part.
Good luck and keep us posted.
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Old Oct 28, 2024 | 04:49 PM
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Originally Posted by GOPHIMBO
So i've got the infamous DTC 0521 / P2004 "The charge movement flap (cylinder bank 1) has a malfunction" along with multiple misfires, rough idling, poor acceleration... Got a Pierburg shipping from FCP. Time to open her up. Hope i don't screw up.. Anything else I should do while I'm at it? Tips??

https://cimg5.ibsrv.net/gimg/www.mbw...c5d2a1aee.jpeg
Originally Posted by 01blackhawk
Good luck man, I`m always in between for this job, part of me says you can do it, part of me like naaahh, I have a 272 and 273 engines at the moment both are about 140K miles and ok at the moment but I know sooner or later I will have to do it.
I saw a very detailed video a few weeks ago that boosted my confidence.
Only tip I can say is the new holes on the intake manifold will be self tapping, everybody says you need to be careful at that part.
Good luck and keep us posted.
Good luck! Agree, quite a job, hope everything goes out smoothly : )
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Old Oct 28, 2024 | 07:39 PM
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Go slow, and keep the magnetic dropped bolt retriever thingy handy! . Best thing HF sells imo
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Old Oct 28, 2024 | 09:31 PM
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make sure to also replace the injector seals and intake gaskets while at it
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Old Oct 29, 2024 | 03:31 AM
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Beat of luck with that
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Old Oct 29, 2024 | 08:25 AM
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I noticed you disconnected and removed the complete ecu from the top of the manifold. Some of the videos I watched on YT detailing the repair procedure, especially the one from FCP Euro, had just the passenger side disconnected while the driver side remained connected and the ecu resting near the firewall out of the way. I believe MB also recommends it being done this way as well.
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Old Oct 29, 2024 | 09:23 AM
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Originally Posted by Raj1471
I noticed you disconnected and removed the complete ecu from the top of the manifold. Some of the videos I watched on YT detailing the repair procedure, especially the one from FCP Euro, had just the passenger side disconnected while the driver side remained connected and the ecu resting near the firewall out of the way. I believe MB also recommends it being done this way as well.
This is the one I'm following. He mentioned in the comments that he removed the ECU many times on this repair with no issues. I did disconnect the battery before I disconnected the ECU if they even matters but we'll see once I have everything put back together.

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Old Oct 29, 2024 | 09:24 AM
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Originally Posted by 01blackhawk
Good luck man, I`m always in between for this job, part of me says you can do it, part of me like naaahh, I have a 272 and 273 engines at the moment both are about 140K miles and ok at the moment but I know sooner or later I will have to do it.
I saw a very detailed video a few weeks ago that boosted my confidence.
Only tip I can say is the new holes on the intake manifold will be self tapping, everybody says you need to be careful at that part.
Good luck and keep us posted.
Hope I don't jinx you but my W212 was exactly 140k when I got this problem. lol
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Old Oct 29, 2024 | 09:26 AM
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Originally Posted by Jaybird123
Go slow, and keep the magnetic dropped bolt retriever thingy handy! . Best thing HF sells imo
Oh yea I got one ready. I've lost my fair share of bolts down the black hole for sure. haha.
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Old Oct 29, 2024 | 09:27 AM
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Originally Posted by tesna
make sure to also replace the injector seals and intake gaskets while at it
yea, i got the complete kit from FCP Euro and it comes with all the gaskets except for the throttle body one. I bought that one separately.
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Old Oct 29, 2024 | 06:28 PM
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Originally Posted by GOPHIMBO
This is the one I'm following. He mentioned in the comments that he removed the ECU many times on this repair with no issues. I did disconnect the battery before I disconnected the ECU if they even matters but we'll see once I have everything put back together.
https://www.youtube.com/watch?v=6H28pxrfs2c&t=657s
Yeap, this was the video I was talking about, this guy is really good and going thru all the details, gave me confidence that I can deal with it.
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Old Oct 29, 2024 | 08:34 PM
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Though you probably already know this, but protect any openings to the sky from bolts, nuts, and dirt.
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Old Oct 29, 2024 | 11:30 PM
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Originally Posted by JettaRed
Though you probably already know this, but protect any openings to the sky from bolts, nuts, and dirt.
yup, it's definitely on my checklist. thanks!
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Old Nov 2, 2024 | 06:32 PM
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This confirms it. one of the levers are broken.
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