[ezzo]

This video shows that cleaning the inside of the manifold may be required due to the build-up of oil gunk and carbon.

On a second note, I got the infamous P2006.
So, I need to replace the tumble flaps lever that broke at the ball connecting the diaphragm plastic rod. Could you share where you got the metal lever?

Finally, is everyone absolutely sure there is no way I can do this without the intake manifold from the car? What if I remove the auxiliary air pump and whatever is around it?

 

[ezzo]

Hi all,
I am going to change the oil separator pan and cover (passenger side), and the oil breather (driver side). Thanks for the heads up. However that is now the least of my worries.

I took the manifold out and the lever is indeed broken at the ball joint with the center diafragm. I'm not planning on putting a new manifold. Instead, I cleaned it up to almost new condition. I was not planning on opening it up. Unfortunately, I discovered that while all arms and flaps are intact (and really solidly built), the bushings are broken. What I'm talking about are small plastic pieces that are used along each of the runner flaps' arms to help the arm rotate without wobbling. There are 13 of them. Six on the driver side, and 7 on the passenger side. All the ones on the driver's side are broken but were still functioning, except for one that had a piece missing, most probably while washing it. All the broken bushings were a catastrophe waiting to happen. They are not hard plastic, but they sure can damage the valves or pistons if sucked inside the cylinder.

I'm going to buy the repair kit with those little seats to rebuild my manifold. I have more time to spare than pay $650 on the A2721402401 manifold (FCP Euro price).
I found them on walmart.com (https://www.walmart.com/ip/For-Merc...etal-Flap-RK5691M-Air-Intake-Manifold-Repair-Kit-05-06-07-08-09-10-11/836349788)

I'm attaching pictures here to show you what I mean.