ml3204me

If you drive your vehicle long enough chances are you will experience an air intake manifold failure. Usually accompanied by CEL with Error code p2006, misfires, lean error codes etc. This Video explains the failures and how you can avoid it.

C230 Sport Coup

Here's a kit with the actual rod as well as the center piece.
https://www.ecstuning.com/b-uro-part...1402401r-prm~/
Now to find a mechanic who will do the job, 'cause I really don't want to.
What all would I need? new gaskets, injector seals? Input appreciated.

mrobinso

I just learned the hard way about this. We purchased our 2011 ML350 a month or two ago from a private seller. I buy and sell a lot of cars so didn't feel the need for a PPI. I usually do most of the work on our cars myself, but with a brand new baby in the family, I took it to my indy mechanic for a checkup and fluid service (transmission, coolant, brake fluid, transfer case).

Received the call that the notorious intake manifold lever was broken on our manifold. The shop owner knows his stuff, but has a business to run and prefers to go by the book. MB recommends replacing the whole intake manifold - which is stupid in my view as the small lever can be replaced. However, my mechanic recommended an OEM replacement anyway, saying they have used the replacement repair kit for the lever before and it was okay for a while but the car they installed it on ended up needing a new intake in the end as the part of lever (on the inside of the intake) was not engaging like the OEM one did. I thought that was a bunch of baloney, but with the new baby I didn't have the full day needed to remove my intake, install the repair kit, and re-install the intake. My wife would have killed me if I abandoned her with the baby for a weekend in the garage!

My indy did install a new intake to the tune of $2,000. I just bit the bullet and paid as again - new baby. The breakout was $1,100 for the OEM Mercedes intake manifold (this is a fair price for the MB intake, but there is an aftermarket manifold out there made by Pierburg that can be had for about $500) and $900 for labor. I talked to the shop owner afterwards he said his shop takes about half a day to remove the intake and another half a day to install the new one, then about another hour or two spent running it, clearing codes, driving it around town to make sure no issues/confirming no new codes.

So moral of the story, get a PPI, but if you have the time to do this repair yourself it is certainly doable for a shade tree, but you'll need to take your time and I would guess this is a full weekend job, assuming you aren't working on it all day straight.

I saved a couple of helpful links about how to repair this with the replacement lever kit, since I considered doing it myself:

How to remove intake manifold (this is for a w204 but should be similar to our cars): http://www.pelicanparts.com/techarti...ld_Removal.htm

How to repair (again, for a w204): http://www.pelicanparts.com/techarti...tor_Repair.htm

URO repair kit (price averages $165):
http://www.rmeuropean.com/Products/2...253-V7266.aspx

Aftermarket eBay kits with manifold gaskets are plentiful (prices range in the $60-$100 range) - there are several different designs so be careful if you go with one of these: http://www.ebay.com/itm/MotorKing-Me...FRB4-r&vxp=mtr

A helpful YouTube video about replacing the lever:

tritron

It seems you over paid oem intake can be had for around $600 and some labor of love should be free. You could save $500 by buying part yourself. Can you glue it ?

C230 Sport Coup

OEM intake for $600? Where?
After consulting with my mechanic,
he feels that repairing it is a mistake, since as he puts it,
the "potato chip" intake flaps will disintegrate and get sucked into the engine, thereby
"solving" all your problems, as the engine is now garbage.
So doesn't sound like a good plan to repair.

Buy $600 for the intake? WHERE?
I see the Pierburg for that price. Not
the OEM mercedes part.

Also, I was quoted 5 hours at $100 for labor.

tritron

Few places have them or
http://www.ebay.com/itm/Factory-Merc...JYG8De&vxp=mtr
Or rebuild part http://www.rebuildmastertech.com/mer...et-2721402401/

mrobinso

Inherently my Indy has a markup on parts, but I thought the price for the manifold was about market, as it was the price I found for an OEM Mercedes intake on RMEuropean and PelicanParts. Your eBay manifold looks good though.

C230 Sport Coup

Except all he has is a picture of a box.
Odd.

ml3204me

May I stress that these manifolds are failing because oil/soot is getting into the air intake manifold via a worn crankcase rebreather valve; once the internal flaps get sooted up they become harder to move and the external part breaks...

Get a used/rebuilt intake manifold from (online) and most importantly... Change that Rebreather on the crankcase:

Video here:

C230 Sport Coup

Very interesting, is that you on the video?
Our ML has been using a bit of oil lately, perhaps now i know why!
Any idea on the pn?