Remove/Install Resonance Intake Manifold - AR09.20-P-1961GQ

ENGINE 276.9 in MODEL 166, 251 

Shown on model 166.0 

Shown on model 166.0 

	Risk of injury  caused by fingers being jammed or pinched when removing, installing or aligning hoods, doors, trunk lid/rear-end door or sliding roof.	No parts of the body or limbs should be within the operating area when the components are moving.	AS00.00-Z-0011-01A
	Notes on avoiding damage through contamination and foreign objects		AH00.00-P-5000-01A
	Remove/install
1	Switch off ignition
2	Remove front engine cover
3	Remove windshield wiper system	ENGINE 276.9 in MODEL 251	AR82.30-P-6400RT
4	Remove partition wall between wheel wells	ENGINE 276.9 in MODEL 251	AR62.30-P-2400RT
5	Remove air filter housing (8) with engine air intake duct (9) upstream of air filter	Bolt, air filter to cylinder head cover	*BA09.10-P-1001-01M
		Bolt, air filter to air intake pipe support brace	*BA09.10-P-1002-01M
6	Remove bulkhead (78)	ENGINE 276.9 in MODEL 166
7	Remove purge line (4) on intake manifold (1)
8	Detach vent line (5) at air intake hose (2) and unclip at intake manifold (1)
9	Detach bleed line (11) at intake manifold (1)	Replace seal.
10	Disconnect electrical connection at pressure sensor downstream of throttle valve (B28/7)
11	Disconnect electrical connection at throttle valve actuator (M16/6)
12	Unclip electrical line at throttle valve actuator (M16/6)	The retaining clip for electrical line is located under the throttle valve actuator (M16/6).
13	Detach vacuum line (7) for brake booster on intake manifold (1) and vacuum pump
14	Detach vacuum line (6) to vacuum pump
15	Disconnect electrical connection on intake manifold intake air temperature sensor (B17/1)
16	Disconnect electrical connections on intake manifold selector drum switchover valve (Y77/3) and intake manifold resonance flap switchover valve (Y77/2)
17	Remove cover (1a) on intake manifold (1)	Bolt, model plate cover to air intake pipe	*BA09.20-P-1008-01T
18	Remove screw/bolts (1s) for intake manifold (1) on connecting flange (1l, 1r)	Bolt, air intake pipe to intermediate flange	*BA09.20-P-1001-01T
19	Remove intake manifold (1)	Cover connecting flange (1l, 1r) with rags. Replace seals (13).
	Only perform operation steps 20 to 25 when removing the connecting flanges (1l, 1 r) for intake manifold (1)
20	Remove screw/bolts (14, 15) on right connecting flange (1 r)	Bolt, intermediate flange to cylinder head	*BA09.20-P-1002-01T
		Bolt, intermediate flange to intermediate flange	*BA09.20-P-1003-01T
21	Remove right connecting flange (1 r)	Replace seals (12).
22	Remove bracket (1) from EGR line (16)	Turn bracket (1 h) to the left to remove. Installation: Ensure correct seating of the bracket (1h).
23	Remove screw/bolt (17)	Bolt, EGR line to bracket	*BA14.20-P-1005-01M
24	Remove screw/bolts on left connecting flange (1l)	Bolt, intermediate flange to cylinder head	*BA09.20-P-1002-01T
25	Remove left connecting flange (11)	Cover intake port with rags. Replace seals (12).
26	Install in the reverse order
27	Risk of accident  from vehicle starting off by itself when engine running. Risk of injury  (bruises and burns) resulting from working on the engine while it is being started or when it is running. Carry out engine test run and check intake manifold (1) for leaktightness	Secure vehicle to prevent it from starting off by itself. Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts.	AS00.00-Z-0005-01A