Remove/install resonance intake manifold

AR09.20-P-1961RX

Remove/install resonance intake manifold

28.8.08

26.6.08

Notes on avoiding damage through contamination and foreign objects, added

 

Remove/install



Notes on avoiding damage through contamination and foreign objects

AH00.00-P-5000-01A



Information on preventing damage to electronic components due to electrostatic discharge

AH54.00-P-0001-01A

1

Turn key in ignition lock to position "0"

 On vehicles with code (889), Keyless-Go: Press Keyless-Go start/stop button repeatedly until ignition is switched off.

Remove the Keyless Go transmitter card or transmitter key from the vehicle and store beyond the reach of the transmitter (min.

2 m).

2

Remove air filter housing

AR09.10-P-1150RX

3

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

4

Disconnect electrical connectors (1a, 1b)

5

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

 Installation: Install new cable ties.

6

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

 Installation: Install new cable ties.

7

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).

8

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

AR07.07-P-1453RX

9

Remove air duct housing (4)

AR09.20-P-0080RX

10

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

11

Remove right control unit bracket (3r)



*BA07.08-P-1002-01A

12

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



*BA15.18-P-1001-01B



*BA15.18-P-1002-01B



*BA15.18-P-1003-01B

13

Remove left rear engine lifting eye (8)



*BA01.30-P-1005-01O

14

Unlock and disconnect electrical connectors at fuel injection valves (Y62), throttle valve actuator (M16/6) and electrical air pump (M33)

15

Release and disconnect electrical connectors at the position sensors (B28/9, B28/10)

Model 230.455 /456 /457 /471

16

Disconnect electrical connector (9)

17

Release fuel pressure over service valve (10)

AR07.03-P-1460-01VA



*BA07.03-P-1004-01B



*119589046300

18

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

 Seal connections immediately with stop plugs.



*129589009100



*BA07.03-P-1001-01B

19

Remove bolts (7a)



*BA09.20-P-1001-01N

20

Lift front intake manifold (7) and disconnect pneumatic lines (12) from the connection fittings on intake manifold (7)

21

Take out intake manifold (7)

 Installation: Replace seals (7b).

22

Cover openings in cylinder heads

 Installation: Objects that have entered the intake tract must always be removed before fitting intake manifold (7) otherwise engine damage may occur.

23

Detach left control unit bracket (3l), fuel distributor (2) with fuel injection valves (Y62) and throttle valve actuator (M16/6)

When replacing intake pipe (7).



*BA07.08-P-1002-01A



*BA07.03-P-1002-01B



*BA07.61-P-1001-01D

24

Detach position sensors (B28/9, B28/10) from intake manifold (7)

Model 230.455 /456 /457 /471

When replacing intake pipe (7).



*BA09.20-P-1002-01N

25

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

26

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

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

BA01.30-P-1005-01O

Bolt, lifting eye to cylinder head

M8

Nm

20

20

Number

Designation

Engine
272

Engine
273

BA09.20-P-1001-01N

Bolt, resonance intake manifold to cylinder head

Nm

9

9

BA09.20-P-1002-01N

Bolt, tumble flap position sensor to resonance intake manifold

Nm

6

6

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

BA07.61-P-1001-01D

Bolt, throttle valve actuator to resonance intake manifold

Nm

9

9