Remove, install resonance intake manifold

AR09.20-D-1961US

Remove, install resonance intake manifold

1.8.07

 

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.
Only pour fuels into suitable and appropriately marked containers.

Wear protective clothing when handling fuel.

AS47.00-Z-0001-01A

1

Remove ME-SFI control unit (N3/23)

AR07.08-D-7008US

2

Remove air duct housing

AR09.20-D-0080US

3

Disconnect vacuum line (9) on resonance intake manifold (1)

4

Disconnect electrical connector on throttle valve positioner (M16/5)

5

Disconnect electrical connector (11)

6

Remove electrical line (18) on left control unit holder (17)

 Installation: Install new cable ties.

7

Disconnect electrical connector (15) f and remove on fuel distributor (12)

8

Disconnect hoses (16) for crankcase ventilation system

 Detach hoses (16) on Y-fitting.

9

Disconnect electrical connector (2)

10

Disconnect electrical connector (7)

11

Remove right control unit holder (8)



*BA07.08-N-1002-01A

12

Remove bolts (5) on right lifting eye (6) and left lifting eye (14)



*BA01.30-N-1004-01R

13

Remove right feed line duct (4) and left feed line duct (10)



*BA15.18-N-1002-01D



*BA15.18-N-1001-01D

14

Remove rear feed line duct on resonance intake manifold (1)



*BA15.18-N-1001-01D

15

Disconnect electrical connector on left position sensor intake manifold swirl flap (B28/9) and right position sensor intake manifold swirl flap (B28/10)

16

Remove electrical connectors at fuel injection valves (Y62/1, Y62/2, Y62/3, Y62/4, Y62/5, Y62/6)

17

Reduce fuel pressure with the pressure hose via the service valve (3)

AR07.03-D-1460-01US



*BA07.03-N-1003-01G



*119589046300

18

Remove fuel line (13) on fuel distributor (12) and seal connections with a suitable stop plug

 Catch escaping fuel with an absorbent rag.



*BA07.03-N-1001-01G

19

Remove bolts (21)



*BA09.20-N-1001-01B

20

Lift resonance intake manifold (1) to the front and detach vacuum hoses (19) from connection fittings on resonance intake manifold (1)

 Detach vacuum hoses (19) carefully; the connection fittings on the resonance intake manifold (1) can break.

 Installation: Check vacuum hoses (19) for damage; replace if necessary.

21

Remove resonance intake manifold (1) and close off openings for intake tract of cylinder head using rags

 Installation: Clean sealing surfaces.

Clip new seals (20) onto resonance intake manifold (1).

22

Remove left control unit holder (17) on resonance intake manifold (1)

 When replacing resonance intake manifold (1).



*BA07.08-N-1002-01A

23

Remove fuel distributor (12) with fuel injection valves (Y62/1, Y62/2, Y62/3, Y62/4, Y62/5, Y62/6) on resonance intake manifold (1)

 When replacing resonance intake manifold (1).

 Installation: Replace O rings on fuel injection valves (Y62/1, Y62/2, Y62/3, Y62/4, Y62/5, Y62/6).



*BA07.03-N-1002-01G

24

Detach throttle valve actuator (M16/5) on resonance intake manifold (1)

 When replacing resonance intake manifold (1).

 Installation: Replace seal on brake booster (M16/5)



*BA07.61-N-1001-01A

25

Remove left intake manifold swirl flap position sensor (B28/9) and right intake manifold swirl flap position sensor (B28/10) on resonance intake manifold (1)

 When replacing resonance intake manifold (1).



*BA09.20-N-1002-01B

26

Install in the reverse order

 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

27

Test run engine and check engine for leaks around resonance intake manifold (1)

Number

Designation

Engine
272.979
in model
906

BA01.30-N-1004-01R

Bolt connecting suspension lug to cylinder head

M8

Nm

18

Number

Designation

Engine
272
in model
906

BA07.03-N-1001-01G

Union nut, fuel feed line to fuel distributor

Nm

24

BA07.03-N-1002-01G

Bolt connecting fuel distributor to resonance intake manifold

Nm

14

BA07.03-N-1003-01G

Protective cap to service valve

Nm

15

Number

Designation

Engine
272.979
in model
906

BA07.08-N-1002-01A

Bolt, control unit holder to resonance intake manifold

Nm

10

Number

Designation

Engine
272.979
in model
906

BA07.61-N-1001-01A

Bolt, throttle valve actuator to resonance intake manifold

Nm

10

Number

Designation

Engine
272.979
in model
906

BA09.20-N-1001-01B

Bolt connecting resonance intake manifold to cylinder head

Nm

9

BA09.20-N-1002-01B

Bolt, intake manifold swirl flap position sensor to resonance intake manifold

Nm

6

Number

Designation

Engine
272
in model
906

BA15.18-N-1001-01D

Bolt, feed line duct to resonance intake manifold

Nm

8

BA15.18-N-1002-01D

Bolt, feed line duct to cylinder head cover

Nm

8