M272 Engine
287 HO M272 (FAH) 10/05/04
Objectives
Students will be able to:
identify differences between M112 and M272
explain the camshaft adjusters operation
identify major components of the M272
explain function of the swirl flaps
explain function of the temperature management system
Contents
Comparison
Highlights
Motor mechanicals
Oil level switch
Crankcase ventilation
Cylinder head
Intake manifold
ME 9.7
Crank sensor
O2 sensors
Three way catalytic converters
Ignition coil
Mass airflow
Temperature management
Fuel tank
Speed sensitive power steering
4
6
9
12
16
18
29
40
46
49
50
52
54
55
59
64
3
M272 M112 Comparison
M272
3.5 litre
M112
3.2 litre
268 hp @ 6000 rpm
214 hp @ 5700 rpm
258 lb-ft @ 2500 to 5000 rpm 228 lb-ft @ 5700 rpm
Compression Ratio 10.7 : 1
Compression Ratio 10.0 : 1
Sparkplugs per cylinder 1
Sparkplugs per cylinder 2
ME 9.7
ME 2.8
Coil On Plug
Double ignition coils
Comparison
190 kW
160
power kW
Blue line (solid ) =
M272
4 valve
180 kW
180
Red line (Dash) =
M112 3 valve
400
380
350 Nm
360
140
340
120
320
Torque Nm
200
M272
100
300
M112
80
280
60
260
40
240
20
220
0
1000
2000
3000
4000
5000
6000
200
7000 RPM
New M272 introduced in the new SLK 171
Lets look at some highlights
M272 HighLights
M112 replacement
3.5 litre displacement
Counter rotating balance shaft
Stiffer engine with lateral main
bearing attachments
4 valve continuously variable
camshafts intake and exhaust
(DOHC)
M272 HighLights
90 degree V-6
Two stage Intake manifold
Turbulence flaps in the
intake ports
ME 9.7 control unit
mounted on top of engine
Electrically assisted
thermostat
No EGR valve
Both cams adjust
8
Lets take a look at what changed mechanically
Motor Mechanicals
Based off of M112 engine
Bore and Stroke increase
compared to M112
Die cast aluminum crankcase
Silitec coated cylinder liners
Starter openings both sides of block
8 lateral main bearing bolts
10
Crankshaft
Crankshaft lighter as compared to M112
Wider main bearings as compared to M112
used to reduce vibration
Iron coated cast aluminum pistons
11
Balance shaft, familiar function
Oil sensor, now a switch
12
Balance Shaft
Balance shaft similar to the M112
Balance shaft rotates opposite
crankshaft
13
Oil Level Switch
Reed contact oil level switch S43 replaces
B40
Only one pin of the two pin connector used
S43 mounted in oil pan
Chain driven oil pump
Vehicle equipped with an oil level dipstick
14
Partial and full load crankcase ventilation system
15
Crankcase Ventilation
16
Cylinder head
4 valves
DOHC
Cam adjusters
17
Cylinder Head
New design cast aluminum cylinder heads
4 overhead camshafts (DOHC)
4 valves per cylinder, improve torque
and horsepower compared to 3 valve
engines
Camshaft upper bearing surfaces
integrated into cam housing cover
Nickel coated high strength
steel exhaust valves
18
Cylinder Head
4 Cam adjusters
4 Cam Sensors
ME can detect Cam position
with ignition on
Intake cam is chain driven and
drives exhaust cam via gear
19
Chain Tensioner
Step type chain tensioner with internal spring
Located at the lower right front engine
Must be manually reset if removed
Failure to preset tensioner before
assembly will result in engine damage
20
Camshaft Timing Adjusters
Vane type, oil pressure controlled
adjusters
Continuously variable
40 advanced for intake (from 4
BTDC to up to 36 ATDC)
40 retard for exhaust (from 30
BTDC to up to 10 ATDC)
21
Exhaust Cam Gear
Note: Retaining nut at front timing adjuster is reverse thread
22
Camshaft Position Sensors
4 Hall effect sensors, one for
each camshaft
True Power On (TPO) sensor
technology capable of detecting
cam position with stationary
engine
Right and left camshaft signals
staggered by 240 camshaft
angle
Signal is low in absence of a
window
23
Impulse Wheels
Four impulse wheels used on the
M272 mounted on the front of each
camshaft timing adjuster
Each impulse wheel has a different
part number
The openings of the impulse wheels
help ME determine the camshafts
exact position
Can only be used one time!
If new impulse wheels are not used
the pins could shear off causing
massive damage to adjusters
Both locating pins sheared
off when reinstalled
Gouging of
mounting surface
24
Exhaust Cam Gear
Exhaust Cam 2 piece gear
Smaller outer gear spring
loaded for noise reduction
Gear must be held in place
prior to disassembly
Segment Ring must be
replaced once removed
Adjuster bolt reverse
threaded
25
Camshaft Timing Network
B6/4 Camshaft position sensor
(intake left)
B6/6 Camshaft position sensor
(exhaust left)
B6/7 Camshaft position sensor
(exhaust right)
B6/5 Camshaft position sensor
(intake right)
B11/4 Engine coolant
temperature sensor
B70 Crankshaft hall sensor
B2/5 MAF
N3/10 ME 9.7
Y49/5 Camshaft timing control
solenoid (exhaust right)
Y49/7 Camshaft timing control
Solenoid (Intake right)
Y49/4 Camshaft timing control
solenoid (intake left)
Y49/6 Camshaft timing control
Solenoid (exhaust left)
26
Camshaft Position
Remove camshaft sensors
Align balancer (305) to front cover pointer
Check impulse wheels stamped numbers
If above line up properly cam positions
are correct
27
Camshaft Timing Basic Position
1. Align balancer to 40 ATDC
to front cover pointer
2. Front cover pointer
2
1
3. Upper camshaft marks
4. Camshaft marks aligned to head
28
Intake
Variable runners
Swirl flaps
29
Intake Manifold
Magnesium cast sectional
intake manifold with
integrated vacuum reservoir
Variable intake runner
Short runner for higher RPM
Long runner for lower RPM
Swirl-Flaps also added
providing better fuel mixture
30
Intake Components
12 Intake manifold with integral vacuum reservoir
12/1 Swirl flap shaft, left cylinder bank
12/2 Swirl flap shaft, right cylinder bank
12/3 Longitudinal switch flap shaft, right cylinder bank
12/4 Longitudinal switch flap shaft, left cylinder bank
22/6 Intake manifold switchover diaphragm
22/9 Swirl valve switchover diaphragm
Y22/6 Variable intake manifold switchover valve
Y22/9 Intake manifold swirl flap switchover valve
31
Variable Length Intake Manifold
Engine load over 50% from approx.
1750 RPM intake flaps closed (long runner)
Better cylinder filling and increased
torque
Above 3900 RPM switchover solenoid
deactivated via ME intake flaps open
(short runner)
Incoming air follows short runner
Vacuum applied
Long runner
No Vacuum applied
Short runner
Unlike M112, M272 has two diaphragm
actuators
32
Intake Functional Diagram
A Long runner
B Short runner
1- Switchover flaps
12 Intake manifold with integral
vacuum reservoir
B2/5 Hot film mass airflow sensor
22/6 Intake manifold switchover diaphragm
Y22/6 Variable intake manifold switchover valve
M16/6 Throttle valve actuator
B70 Crankshaft hall sensor
N3/10 ME 9.7
33
Swirl Flaps
Under certain operating conditions intake
air is swirled via swirl flap
for improved mixture process
Vacuum diaphragm driven by ME
controls flap position
Swirl flap position sensors (hall sensors) monitor
2 magnets attached to swirl flap actuating shafts
to determine flap position (activated/not activated)
B28/9
B28/10
Swirl flap position sensors
Sensors located at rear of intake manifold
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