Remove/install resonance intake manifold - AR09.20-P-1961GZA
ENGINE 272, 273 in MODEL 164, 251
ENGINE 273 in MODEL 463
Shown on engine 272
Shown on engine 272
MODIFICATION NOTES
| 20.8.09 | Remove power electronics with power distributor | Step 1.2 | AR08.10-P-0011GZH |
| 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. Only pour fuels 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 | ||
| 1.1 | Remove air filter housing | Model 164 (except 164.195), 251 | AR09.10-P-1150GZA |
| Model 463 | AR09.10-P-1150GZG | ||
| 1.2 | Remove power electronics with power distributor | Model 164.195 | AR08.10-P-0011GZH |
| 2 | Disconnect right connector (R) at ME-SFI [ME] control unit (N3/10) | Except 164.195 | |
| 3 | Disconnect electrical connectors (1a, 1b) | ||
| 4 | Detach jack of electrical connector (1b) on fuel distributor (2) | ||
| 5 | Detach electrical feed line (1c) from left control unit bracket (3l) | ||
| 6 | Pull ME-SFI [ME] control unit (N3/10) out of left control unit bracket (3) and place to one side | Except 164.195 |
|
| 7 | Remove hot film mass air flow sensor (B2/5) | Model 164, 251 | AR07.07-P-1453GZA |
| Model 463 | AR07.07-P-1453GZG | ||
| 8 | Remove air duct housing (4) | AR09.20-P-0080GZA | |
| 9 | Disconnect hoses (5a, 5b) from crankcase ventilation system | ||
| 10 | Remove right control unit holder | *BA07.08-P-1002-01A | |
| 11 | Detach feed duct (6a) from cylinder head cover and intake manifold (7) | *BA15.18-P-1001-01B | |
| *BA15.18-P-1002-01B | |||
| 12 | Detach feed duct (6b) from intake manifold (7) | *BA15.18-P-1001-01B | |
| 13 | Remove left rear engine lifting eye (8) | *BA01.30-P-1005-01O | |
| *BA15.18-P-1003-01B | |||
| 14 | Remove feed duct (6c) from cylinder head cover | *BA15.18-P-1002-01B | |
| 15 | Release and disconnect the electrical connectors on fuel injection valves (Y62) | ||
| 16 | Unlock electrical connectors on position sensor for left intake manifold tumble flap (B28/9) and position sensor for right intake manifold tumble flap (B28/10) and disconnect | ||
| 17 | Disconnect electrical connector (9) | ||
| 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 with the pressure hose via the service valve (10) | AR07.03-P-1460-01GZ | |
| *BA07.03-P-1004-01B | |||
| Fig 3 | |||
| 21 | Disconnect fuel line (11) from fuel distributor (2) | ||
| *BA07.03-P-1001-01B | |||
| Fig 4 | |||
| 22 | Remove bolts (7a) | *BA09.20-P-1001-01N | |
| 23 | Raise intake manifold (7) at front and detach pneumatic lines (12) from the connection fittings on intake manifold (7) | ||
| 24 | Take out intake manifold (7) | ||
| 25 | Cover openings in cylinder heads | ||
| 26 | Detach left control unit bracket (3l) from intake manifold (7) | ||
| *BA07.08-P-1002-01A | |||
| 27 | Detach fuel distributor (2) with fuel injection valves (Y62) from intake manifold (7) | ||
| *BA07.03-P-1002-01B | |||
| 28 | Detach throttle valve actuator (M16/6) from intake manifold (7) | ||
| *BA07.61-P-1001-01D | |||
| 29 | Detach position sensor for left intake manifold tumble flap (B28/9) and position sensor for right intake manifold tumble flap (B28/10) from intake manifold (7) | ||
| *BA09.20-P-1002-01N | |||
| 30 | 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 | |
| 31 | 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, 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 | - | ||
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 |
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 |