Remove/install resonance intake manifold - AR09.20-P-1961TS
ENGINE 272, 273 (except 272.985) in MODEL 211, 219
| Remove/install | |||
| 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) | 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) | ||
| 6 | Remove electrical feed line (1c) from left control unit bracket (3l) | ||
| 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 | ||
| 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 | |||
| Figure | |||
| 23 | Disconnect fuel line (11) from fuel distributor (2) | ||
| Fig 3 | |||
| *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) | ||
| 27 | Cover openings in cylinder heads | ||
| Remove components from 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 | |||
| 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 |
CONTROL UNIT
| Number | Designation | Engine 272 | Engine 273 | |
|---|---|---|---|---|
| BA07.08-P-1002-01A | Bolt from 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 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 |
CYLINDER HEAD
| Number | Designation | Engine 272 | Engine 273 | ||
|---|---|---|---|---|---|
| BA01.30-P-1005-01O | Bolt from 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 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 | - | ||
INTAKE MANIFOLD
| Number | Designation | Engine 272 | Engine 273 | |
|---|---|---|---|---|
| BA09.20-P-1001-01N | Bolt from resonance intake manifold to cylinder head | Nm | 9 | 9 |
ME-SFI [ME] GASOLINE INJECTION AND IGNITION SYSTEM
| Number | Designation | Engine 272 | Engine 273 | |
|---|---|---|---|---|
| BA07.61-P-1001-01D | Bolt from throttle valve actuator to resonance intake manifold | Nm | 9 | 9 |