Remove/install resonance intake manifold

AR09.20-P-1961VA

Remove/install resonance intake manifold

16.12.08

 

Remove/install



Notes on avoiding damage to ignition system

AH15.10-P-0002-01V

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

1

Turn key in ignition lock (electronic ignition switch control unit) to position "0"

2

Open engine hood and raise to vertical position

AR88.40-P-1000V

3

Remove air filter housing

AR09.10-P-1150VA

4

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

5

Detach ME control unit (N3/10) from control unit brackets (4a, 4b) and lay to one side

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

6

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

AR07.07-P-1453VA

7

Remove air duct housing

AR09.20-P-0080VA

8

Detach brake booster pneumatic line (1) from intake manifold (2) and set aside

AR43.10-P-0355VA

9

Disconnect hoses (3a, 3b) on crankcase ventilation system

10

Remove right control unit bracket (4a)



*BA07.08-P-1002-01A

11

Detach feed duct (5a) from cylinder head cover and intake manifold (2)



*BA15.18-P-1001-01B



*BA15.18-P-1002-01B

12

Detach feed duct (5b) from intake manifold (2)



*BA15.18-P-1001-01B

13

Remove left rear engine lifting eye (10)



*BA01.30-P-1005-01O



*BA15.18-P-1003-01B

14

Detach feed line duct (5c) from cylinder head cover



*BA15.18-P-1002-01B

15

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

16

Release and disconnect electrical connectors from the tumble flap position sensors of LH and RH intake manifold (B28/9, B28/10)

Except model 171.458

17

Disconnect electrical connector (6)

18

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

19

Disconnect electrical connector from electrical air pump (M33)

20

Reduce fuel pressure through service valve

AR07.03-P-1460-01VA



*BA07.03-P-1004-01B



*119589046300

21

Detach fuel line (8) from fuel distributor (7)

 Catch escaping fuel with an absorbent rag!

 Seal connections immediately with stop plugs.



*129589009100



*BA07.03-P-1001-01B

22

Remove bolts (2a)

 Installation: Observe bolt diagram.

AR09.20-P-1310-03VA



*BA09.20-P-1001-01N

23

Lift front intake manifold (2) and disconnect pneumatic lines (9) from the connection fittings at intake manifold (2)

24

Take out intake manifold (2)

 Installation: Replace gaskets (2b).

25

Cover openings in cylinder heads

 Installation: Always remove any objects that have entered the intake tract before mounting the intake manifold (2), otherwise there is a risk of engine damage.

26

Detach LH control unit bracket (4b) from intake manifold (2)

If replacing the intake manifold (2)



*BA07.08-P-1002-01A

27

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

If replacing the intake manifold (2)



*BA07.03-P-1002-01B

28

Detach throttle valve actuator (M16/6) from intake manifold (2)

If replacing the intake manifold (2)



*BA07.61-P-1001-01D

29

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

30

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

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

BA15.18-P-1002-01B

Bolt, feed duct to cylinder head cover

Nm

8

BA15.18-P-1003-01B

Bolt, feed duct to engine lifting eye

Nm

8

Number

Designation

Engine
272

BA01.30-P-1005-01O

Bolt, lifting eye to cylinder head

M8

Nm

20

Number

Designation

Engine 272

BA07.03-P-1001-01B

Union nut, fuel line to fuel distributor

Nm

20

BA07.03-P-1002-01B

Bolt, fuel distributor to resonance intake manifold

Nm

9

BA07.03-P-1004-01B

Protective cap on service valve

Plastic

Nm

2

Metal

Nm

15

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