Remove/install resonance intake manifold

AR09.20-P-1961EWD

Remove/install resonance intake manifold

17.12.09

 

Remove/install

Danger!

Risk of explosion caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel and risk of injury to eyes and skin caused by contact with fuel

No fire, sparks, open flames or smoking.
Pour fuels only into suitable and appropriately marked containers.

Wear protective clothing when handling fuel.

AS47.00-Z-0001-01A



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



The ground line on the battery must always be detached before beginning work on the fuel system otherwise pressure will be lost in the fuel system through opening a vehicle door or the trunk lid

1

Detach ground line from battery

AR54.10-P-0003EW



Notes on battery

AH54.10-P-0001-01A

2

Turn key in ignition lock to position "0"

3

Remove air filter housing

AR09.10-P-1150EWS

4

Disconnect electrical connectors (1) and fold ME-SFI [ME] control unit (N3/10) to the front

5

Remove hot film mass air flow sensor

AR07.07-P-1453EW

6

Remove air duct housing

AR09.20-P-0080EW

7

Remove control unit bracket (2)



*BA07.08-P-1002-01A

8

Disconnect electrical connector (3)

9

Detach vacuum hose (13) from resonance intake manifold (4)

10

Detach crankcase ventilation system (8) on throttle valve actuator (M16/6)

11

Disconnect electrical connector (9) on throttle valve actuator (M16/6).

12

Remove bolt (5) and clamp

13

Remove feed ducts (6a, 6b) from cylinder head covers



*BA15.18-P-1001-01B

14

Disconnect vacuum lines and electrical connector from intake manifold switchover valve (Y22/6)

15

Remove pressure sensor (B28) from coolant line, detach vacuum line and disconnect electrical connector

16

Remove fuel distributor and fuel lines

AR07.03-P-1030EWD

17

Remove bolt (11)

 Installation: Pay attention to ground line.

18

Disconnect electrical connector on fuel temperature sensor (B50)

19

Remove feed line on service valve (51)



*BA07.03-P-1001-01B

20

Unfasten fuel cooler (27) from resonance intake manifold (4)

AR07.16-P-1100EWD

21

Remove bolts (7)



*BA09.20-P-1001-01N

22

Clamp off coolant hoses (12)

23

Lift resonance intake manifold (4) at the front and remove coolant hoses (12) from connecting flange (10)

24

Take out resonance intake manifold (4)

25

Cover openings in cylinder heads

Remove components from resonance intake manifold (4)

 Only perform steps 26 to 29 when replacing resonance intake manifold (4)

26

Detach throttle valve actuator (M16/6)



*BA07.61-P-1001-01D

27

Remove intake manifold switchover valve (Y22/6)

28

Remove fuel lines holder

29

Remove connecting flange (10)

30

Install in the reverse order

31

Pour in coolant and bleed cooling system

 Do not drain off coolant.

AR20.00-P-1142EWS



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

32

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

Number

Designation

Engine 272

BA07.03-P-1001-01B

Union nut, fuel line to fuel distributor

Nm

20

Number

Designation

Engine 272

BA07.08-P-1002-01A

Bolt, control unit bracket to resonance intake manifold

Nm

8

Number

Designation

Engine
272

BA15.18-P-1001-01B

Bolt, feed duct to resonance intake manifold

Nm

8

Number

Designation

Engine 272

BA09.20-P-1001-01N

Bolt, resonance intake manifold to cylinder head

Nm

9

Number

Designation

Engine 272

BA07.61-P-1001-01D

Bolt, throttle valve actuator to resonance intake manifold

Nm

9