Remove/install resonance intake manifold

AR09.20-P-1961EW

Remove/install resonance intake manifold

2.12.09

 

Remove/install



Information on preventing damage to electronic components due to electrostatic discharge

AH54.00-P-0001-01A



Notes on avoiding damage through contamination and foreign objects

AH00.00-P-5000-01A

1

Remove air filter housing

AR09.10-P-1150EWS

2

Disconnect right connector (R) at ME-SFI [ME] control unit (N3/10)

3

Disconnect electrical connectors (1a, 1b)

4

Remove jack for electrical connector (1b) on fuel distributor (2)

5

Remove electrical feed line (1c) from left control unit bracket (3l)

6

Pull ME-SFI [ME] control unit (N3/10) out of control unit brackets (3l, 3r) and place down to one side

 Do not disconnect left connector (L) at ME-SFI [ME] control unit (N3/10).

7

Remove hot film mass air flow sensor (B2/5)

AR07.07-P-1453EW

8

Remove air duct housing (4)

AR09.20-P-0080EW

9

Disconnect hoses (5a, 5b) from crankcase ventilation system

10

Remove right control unit bracket (3r)



*BA07.08-P-1002-01A

11

Detach supply ducts (6a, 6b, 6c) from cylinder head cover, resonance intake manifold (7) and rear right engine suspension lug (8)



*BA15.18-P-1001-01B



*BA15.18-P-1002-01B



*BA15.18-P-1003-01B

12

Disconnect electrical connectors on injection valves and position sensors (B28/9, B28/10)

13

Disconnect electrical connector (9)

14

Disconnect electrical connectors on throttle valve actuator (M16/6) and electric air pump (M33)

15

Release fuel pressure over service valve (10)

AR07.03-P-1460-01VA



*119589046300

Engine 272

*BA07.03-P-1004-01B

16

Disconnect fuel line (11) from fuel distributor (2)

 Seal connections immediately.



*129589009100



*BA07.03-P-1001-01B

17

Remove bolts (7a)



*BA09.20-P-1001-01N

18

Lift resonance intake manifold (7) to front and take out pneumatic lines (12) from connection fittings at the resonance intake manifold (7)

 Installation: Replace seals (7b).

19

Cover openings in cylinder heads

20

Remove left control unit holder (3l), fuel distributor (2) with injection valves (), throttle valve actuators (M16/6) and position sensors (B28/9, B28/10) from resonance intake manifold (7)

When replacing the resonance intake manifold (7)



*BA07.08-P-1002-01A



*BA07.03-P-1002-01B



*BA07.61-P-1001-01D



*BA09.20-P-1002-01N

21

Install in the reverse order



Checking

 Danger!

Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns during starting procedure or when working near the engine as it is running

Secure vehicle to prevent it from moving by itself.
Wear closed and snug-fitting work clothes.
Do not touch hot or rotating parts.

AS00.00-Z-0005-01A

22

Carry out an engine test run and check intake tract and fuel system for leaks

Number

Designation

Engine
272

Engine
273

BA09.20-P-1002-01N

Bolt, tumble flap position sensor to resonance intake manifold

Nm

6

6

Number

Designation

Engine 272

Engine 273

BA07.08-P-1002-01A

Bolt, control unit bracket to resonance intake manifold

Nm

8

8

Number

Designation

Engine
272

Engine
273

BA15.18-P-1001-01B

Bolt, feed duct to resonance intake manifold

Nm

8

8

BA15.18-P-1002-01B

Bolt, feed duct to cylinder head cover

Nm

8

8

BA15.18-P-1003-01B

Bolt, feed duct to engine lifting eye

Nm

8

8

Number

Designation

Engine 272

Engine 273

BA07.03-P-1001-01B

Union nut, fuel line to fuel distributor

Nm

20

20

BA07.03-P-1002-01B

Bolt, fuel distributor to resonance intake manifold

Nm

9

9

BA07.03-P-1004-01B

Protective cap on service valve

Plastic

Nm

2

-

Metal

Nm

15

-

Number

Designation

Engine
272

Engine
273

BA09.20-P-1001-01N

Bolt, resonance intake manifold to cylinder head

Nm

9

9

Number

Designation

Engine 272

Engine 273

BA07.61-P-1001-01D

Bolt, throttle valve actuator to resonance intake manifold

Nm

9

9