Remove/install resonance intake manifold

AR09.20-P-1961TS

Remove/install resonance intake manifold

24.6.08

 

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

1

Switch ignition off, remove ignition key (transmitter key)

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

Remove Keyless Go transmitter card or transmitter key from the vehicle and store beyond transmitter range (min. 2 m).

2

Remove air filter housing

AR09.10-P-1150TS

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

Detach ME-SFI [ME] control unit (N3/10) from left control unit bracket (3l) and right control unit bracket (3r) and lay to one side

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

8

Detach brake booster vacuum hose from resonance intake manifold (7)

Vehicles with Adaptive Brake (ABR)

9

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

AR07.07-P-1453TS

10

Remove air duct housing (4)

AR09.20-P-0080TS

11

Disconnect hose (5a) and hose (5b) for crankcase ventilation system

12

Remove right control unit bracket (3r)



*BA07.08-P-1002-01A

13

Remove feed duct (6a) from cylinder head cover and resonance intake manifold (7)



*BA15.18-P-1001-01B



*BA15.18-P-1002-01B

14

Remove feed duct (6b) from resonance intake manifold (7)



*BA15.18-P-1001-01B

15

Remove left rear engine lifting eye (8)



*BA01.30-P-1005-01O



*BA15.18-P-1003-01B

16

Remove feed duct (6c) from cylinder head cover



*BA15.18-P-1002-01B

17

Release and disconnect the electrical connectors at the fuel injection valves (Y62)

18

Release and disconnect the electrical connectors on the left intake manifold tumble flap position sensor (B28/9) and right intake manifold tumble flap position sensor (B28/10)

19

Disconnect electrical connector (9)

20

Release and disconnect the electrical connector at the throttle valve actuator (M16/6)

21

Disconnect electrical connector from electrical air pump (M33)

22

Release fuel pressure over service valve (10)

AR07.03-P-1460-01VA



*BA07.03-P-1004-01B



*119589046300

23

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

 Catch escaping fuel with an absorbent rag!

 Seal off connections immediately using stop plugs  .



*129589009100



*BA07.03-P-1001-01B

24

Remove bolts (7a)



*BA09.20-P-1001-01N

25

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

26

Take out resonance intake manifold (7)

 Installation: Replace seals (7b).

27

Cover openings in cylinder heads

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

Remove components from resonance intake manifold (7)

Only perform steps 28 to 31 when replacing resonance intake manifold (7)

28

Detach left control unit bracket (3l) from resonance intake manifold (7)



*BA07.08-P-1002-01A

29

Detach fuel distributor (2) with fuel injection valves (Y62) from resonance intake manifold (7)



*BA07.03-P-1002-01B

30

Detach throttle valve actuator (M16/6) from resonance intake manifold (7)



*BA07.61-P-1001-01D

31

Remove left intake manifold tumble flap position sensor (B28/9) and right intake manifold tumble flap position sensor (B28/10) from resonance intake manifold (7)

32

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

33

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 from control unit bracket to resonance intake manifold

Nm

8

8

Number

Designation

Engine
272

Engine
273

BA15.18-P-1001-01B

Bolt from feed duct to resonance intake manifold

Nm

8

8

BA15.18-P-1002-01B

Bolt from feed duct to cylinder head cover

Nm

8

8

BA15.18-P-1003-01B

Bolt from feed duct to engine lifting eye

Nm

8

8

Number

Designation

Engine
272

Engine
273

BA01.30-P-1005-01O

Bolt from lifting eye to cylinder head

M8

Nm

20

20

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 from 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 from resonance intake manifold to cylinder head

Nm

9

9

Number

Designation

Engine 272

Engine 273

BA07.61-P-1001-01D

Bolt from throttle valve actuator to resonance intake manifold

Nm

9

9