Remove/install resonance intake manifold - AR09.20-P-1961CV
ENGINES 272 (except 272.982) in MODEL 204
ENGINES 272, 273 (except 272.982/984) in MODEL 207
| Remove/install | |||
| Information on preventing damage to electronic components due to electrostatic discharge | AH54.00-P-0001-01A | ||
| 1 | Remove air filter housing | AR09.10-P-1150CV | |
| 2 | Disconnect right connector (R) at ME-SFI [ME] control unit (N3/10) | ||
| 3 | Disconnect electrical connectors (1a, 1b) | ||
| 4 | Remove jack for electrical connector (1b) on fuel distributor (2) | ||
| 5 | Remove electrical feed line (1c) from left control unit bracket (3l) | ||
| 6 | Pull ME-SFI [ME] control unit (N3/10) out of control unit brackets (3l, 3r) and place down to one side | ||
| 7 | Remove hot film mass air flow sensor (B2/5) | AR07.07-P-1453CV | |
| 8 | Remove air duct housing (4) | AR09.20-P-0080CV | |
| 9 | Disconnect hoses (5a, 5b) from crankcase ventilation system | ||
| 10 | Remove right control unit bracket (3r) | *BA07.08-P-1002-01A | |
| 11 | Detach supply ducts (6a, 6b, 6c) from cylinder head cover, resonance intake manifold (7) and rear right engine suspension lug (8) | *BA15.18-P-1001-01B | |
| *BA15.18-P-1002-01B | |||
| *BA15.18-P-1003-01B | |||
| 12 | Disconnect electrical connectors on injection valves (Y62) and position sensors (B28/9, B28/10) | ||
| 13 | Disconnect electrical connector (9) | ||
| 14 | Disconnect electrical connectors on throttle valve actuator (M16/6) and electric air pump (M33) | ||
| 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 | |
| 15 | Release fuel pressure over service valve (10) | AR07.03-P-1460-01VA | |
| Fig 4 | |||
| *BA07.03-P-1004-01B | |||
| 16 | Disconnect fuel line (11) from fuel distributor (2) | ||
| Fig 3 | |||
| *BA07.03-P-1001-01B | |||
| 17 | Remove screw/bolts (7a) | *BA09.20-P-1001-01N | |
| 18 | Lift resonance intake manifold (7) to front and take out pneumatic lines (12) from connection fittings at the resonance intake manifold (7) | ||
| 19 | Cover openings in cylinder heads | ||
| 20 | Remove left control unit holder (3l), fuel distributor (2) with injection valves (Y62), throttle valve actuators (M16/6) and position sensors (B28/9, B28/10) from resonance intake manifold (7) | When replacing resonance intake manifold (7) | |
| *BA07.08-P-1002-01A | |||
| *BA07.03-P-1002-01B | |||
| *BA07.61-P-1001-01D | |||
| *BA09.20-P-1002-01N | |||
| 21 | 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 | |
| 22 | 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-1002-01N | Screw/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 | Screw/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 | Screw/bolt, feed duct to resonance intake manifold | Nm | 8 | 8 |
| BA15.18-P-1002-01B | Screw/bolt, feed duct to cylinder head cover | Nm | 8 | 8 |
| BA15.18-P-1003-01B | Screw/bolt, feed duct to engine suspension lug | Nm | 8 | 8 |
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 | Screw/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 | Screw/bolt, 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 | Screw/bolt, throttle valve actuator to resonance intake manifold | Nm | 9 | 9 |