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Home >> Mercedes Benz >> 2007 >> S65 >> Repair and Diagnosis >> Engine Mechanical >> Blowers, Superchargers & Turbochargers >> Air Intake, Turbo Charging -- S-Class (221) >> Testing & Repair >> Remove/install resonance intake manifold - AR09.20-P-1961SX

Remove/install resonance intake manifold - AR09.20-P-1961SX

ENGINE 272, 273 in MODEL 221 

ENGINE 273 in MODEL 216 

Fig 1: Identifying Resonance Intake Manifold Components
G07590219Courtesy of MERCEDES-BENZ USA

Shown on model 221.071 with Active Body Control (ABC) Code 487 

Fig 2: Identifying Resonance Intake Manifold Components - Engine 273.961
G07590220Courtesy of MERCEDES-BENZ USA

Shown on engine 273.961 

REMOVINGINSTALLING Remove/install    
NOTES 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" IMPORTANT Vehicles with Keyless Go, code 889: Press Keyless Go start/stop button repeatedly until 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-1150SX 
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) IMPORTANT Install new cable ties.  
6 Remove electrical feed line (1c) from left control unit bracket (3l) IMPORTANT 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 IMPORTANT Do not  disconnected left connector (L) at ME-SFI [ME] control unit (N3/10).  
8 Remove hot film mass air flow sensor (B2/5)   AR07.07-P-1453SX
9 Remove air duct housing (4)    
10 Disconnect hoses (5a, 5b) from crankcase ventilation system    
11 Remove right control unit bracket (3r) TORQUE SPECIFICATION *BA07.08-P-1002-01A
12 Remove feed duct (6a) from cylinder head cover and resonance intake manifold (7) TORQUE SPECIFICATION *BA15.18-P-1001-01B
    TORQUE SPECIFICATION *BA15.18-P-1002-01B
13 Remove feed duct (6b) from resonance intake manifold (7) TORQUE SPECIFICATION *BA15.18-P-1001-01B
14 Remove left rear engine lifting eye (8) TORQUE SPECIFICATION *BA01.30-P-1005-01O
    TORQUE SPECIFICATION *BA15.18-P-1003-01B
15 Remove feed duct (6c) from cylinder head cover TORQUE SPECIFICATION *BA15.18-P-1002-01B
16 Disconnect electrical connectors at fuel injection valves (Y62)    
17 Disconnect electrical connectors at position sensors (B28/9, B28/10)    
18 Disconnect electrical connector (9)    
19 Disconnect electrical connector at the throttle valve actuator (M16/6)    
20 Disconnect electrical connector from electrical air pump (M33)    
21 Release fuel pressure over service valve (10)   AR07.03-P-1460-01VA
    TORQUE SPECIFICATION *BA07.03-P-1004-01B
    SPECIAL TOOL Figure
22 Disconnect fuel line (11) from fuel distributor (2) IMPORTANT Seal connections immediately.  
    SPECIAL TOOL Fig 3
    TORQUE SPECIFICATION *BA07.03-P-1001-01B
23 Remove bolts (7a)    
24 Lift resonance intake manifold (7) to the front and detach pneumatic lines (12) from connection fittings at resonance intake manifold (7)    
25 Take out resonance intake manifold (7) IMPORTANTInstallation:  Replace seals (7b).  
26 Cover openings in cylinder heads NOTESInstallation:  Objects that have entered the intake tract must always be removed before fitting resonance intake manifold (7) otherwise there may be engine damage.  
IMPORTANT Only perform steps 27 to 30 when replacing resonance intake manifold (7)     
27 Detach left control unit bracket (3l) from resonance intake manifold (7) TORQUE SPECIFICATION *BA07.08-P-1002-01A
28 Detach fuel distributor (2) with fuel injection valves (Y62) from resonance intake manifold (7) TORQUE SPECIFICATION *BA07.03-P-1002-01B
29 Detach throttle valve actuator (M16/6) from resonance intake manifold (7) TORQUE SPECIFICATION *BA07.61-P-1001-01D
30 Detach position sensors (B28/9, B28/10) from resonance intake manifold (7) TORQUE SPECIFICATION *BA09.20-P-1002-01N
31 Install in the reverse order    
INSPECT 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
32 Carry out an engine test run and check intake tract and fuel system for leaks    
INTAKE MANIFOLD

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
CONTROL UNIT

Number Designation Engine 272 Engine 273
BA07.08-P-1002-01A Bolt, control unit bracket to resonance intake manifold Nm 8 8
ENGINE WIRING HARNESS

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
CYLINDER HEAD

Number Designation Engine 272 Engine 273
BA01.30-P-1005-01O Bolt, lifting eye to cylinder head M8 Nm 20 20
INJECTORS, INJECTION VALVES, LINES

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 -
ME-SFI [ME] GASOLINE INJECTION AND IGNITION SYSTEM

Number Designation Engine 272 Engine 273
BA07.61-P-1001-01D Bolt, throttle valve actuator to resonance intake manifold Nm 9 9
Fig 3: Identifying Set Of Stop Plugs (129 589 00 91 00)
G07507854Courtesy of MERCEDES-BENZ USA
Fig 4: Identifying Pressure Hose (119 589 04 63 00)
G04958441Courtesy of MERCEDES-BENZ USA
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