Removing and installing the resonance intake manifold (engine 272) - AR09.20-P-1961VA

ENGINE 272.942 in MODEL 171.454 

ENGINE 272.963 in MODEL 171.456 

Fig 1: Identifying Resonance Intake Manifold Components (1 Of 2)

Courtesy of MERCEDES-BENZ USA

Fig 2: Identifying Resonance Intake Manifold Components (2 Of 2)

Courtesy of MERCEDES-BENZ USA

	Removing/installing
	Risk of explosion  caused by fuel igniting, risk of poisoning  caused by inhaling and swallowing fuel as well as 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.	-
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	Remove the right connector (R) at the 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 remove the left connector (L) at the 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	Remove pneumatic line (1) of brake booster at resonance intake manifold (2) and place to one side.		AR43.10-P-0355VA
9	Disconnect hoses (3a, 3b) on crankcase ventilation system
10	Remove the right control unit bracket (4a)		*BA07.08-P-1002-01A
11	Detach feed line duct (5a) from cylinder head cover and resonance intake manifold (2)	Bolt for feed line duct on resonance intake manifold	*BA15.18-P-1001-01B
		Bolt for feed line duct on cylinder head cover	*BA15.18-P-1002-01B
12	Detach feed line duct (5b) from resonance intake manifold (2)		*BA15.18-P-1001-01B
13	Remove the left rear motor suspension lug (10)	Bolt for motor suspension lug on cylinder head	*BA01.30-P-1005-01O
		Bolt for feed line duct on motor suspension lug	*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 the electrical connectors at the left and the right intake manifold tumble flap position sensor (B28/9, B28/10)
17	Disconnect plug and socket connection (6)
18	Release and disconnect the electrical connector at the throttle valve actuator (M16/6)
19	Disconnect the electrical connector at the electric air pump (M33)
20	Reduce fuel pressure through service valve		AR07.03-P-1460-01VA
		Pressure hose	Fig 3
21	Disconnect the fuel line (8) from the fuel distributor (7)	Intercept the escaping fuel with an absorbent rag! Seal connections immediately with stop plugs.
		Set of plugs	Fig 4
			*BA07.03-P-1001-01B
22	Unscrew screws (2a)	Installation:  Observe the bolt diagram.	AR09.20-P-1310-03VA
		Bolt for resonance intake manifold on cylinder head	*BA09.20-P-1001-01N
23	Lift the resonance intake manifold (2) to the front and detach the pneumatic lines (9) from the connecting pipes at the resonance intake manifold (2)
24	Take out the resonance intake manifold (2)	Installation:  Replace gaskets (2b).
25	Cover the openings in the cylinder heads	Installation:  Objects that have entered the intake tract must always be removed before fitting the resonance intake manifold (2); otherwise there may be engine damage.
26.1	Detach left control unit bracket (4b) from resonance intake manifold (2)	When the resonance intake manifold (2) is replaced
			*BA07.08-P-1002-01A
27.1	Detach the fuel distributor (7) with the fuel injection valves (Y62) from the resonance intake manifold (2)	When the resonance intake manifold (2) is replaced
			*BA07.03-P-1002-01B
28.1	Detach the throttle valve actuator (M16/6) from the resonance intake manifold (2)	When the resonance intake manifold (2) is replaced
			*BA07.61-P-1001-01D
29	Install in reverse order
	Checking
	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 engine	Secure vehicle to prevent it from moving. Wear closed and snug-fitting work clothes. Do not grasp hot or rotating parts.	-
30	Carry out an engine test run and check the intake tract and fuel system for leaks

CONTROL UNIT

Number	Designation		Engine 272
BA07.08-P-1002-01A	Bolt for control unit holder on resonance intake manifold	Nm	8

ENGINE WIRING HARNESS

Number	Designation		Engine 272
BA15.18-P-1001-01B	Bolt for supply cable on resonance intake manifold	Nm	8
BA15.18-P-1002-01B	Bolt for feed line duct on cylinder head cover	Nm	8
BA15.18-P-1003-01B	Bolt for feed line duct on motor suspension lug	Nm	8

CYLINDER HEAD

Number	Designation			Engine 272
BA01.30-P-1005-01O	Bolt for lifting eye on cylinder head	M8	Nm	20

INJECTION NOZZLES, INJECTION VALVES, LINES

Number	Designation		Engine 272 without code 917	Engine 272 with code 917
BA07.03-P-1001-01B	Union nut for fuel feed line on fuel distributor	Nm	20	20
BA07.03-P-1002-01B	Bolt for fuel distributor on resonance intake manifold	Nm	9	9

INTAKE MANIFOLD

Number	Designation		Engine 272
BA09.20-P-1001-01N	Bolt for resonance intake manifold on cylinder head	Nm	9

ME-SFI FUEL INJECTION AND IGNITION SYSTEM

Number	Designation		Engine 272
BA07.61-P-1001-01D	Bolt for throttle valve actuator on resonance intake manifold	Nm	9

Fig 3: Identifying Pressure Hose (119 589 04 63 00)

Courtesy of MERCEDES-BENZ USA

Fig 4: Identifying Set Of Plugs (129 589 00 91 00)

Courtesy of MERCEDES-BENZ USA