E-Box right plenum chamber, removing and installing

Special tools, testers and auxiliary items required

Fig 1: Pry Lever 80-200

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Pry lever 80 - 200

Fig 2: Removing Rubber Seal For Plenum Chamber Cover & Plenum Chamber Cover

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Removing

Remove wiper arms → Wiper arms, removing and installing .
With ignition switched off, disconnect battery Ground (GND) wire → Battery, disconnecting and connecting .
Remove rubber seal - 1 - for plenum chamber cover.
Remove plenum chamber cover - 2 -.

Fig 3: Removing Bolts For Cowl Grill

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Remove bolts - arrows - for cowl grille - 1 - at left and right.
Carefully pull cowl grille off locking mechanism on windshield.

Fig 4: Removing Bolts And Cover For E-Box At Right In Engine Compartment

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E box right plenum chamber, old version:

Remove bolts - arrows -.

CAUTION: Pump-valve unit of heater (left in front of E box) heats up significantly during operation - danger of burns!

Remove cover of E-Box in right plenum chamber.

Fig 5: Prying Off Retaining Clip With Screwdriver And Removing ECM From E-Box

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Carefully pry off mounting bracket - 3 - using screwdriver - arrows 1 and 2 - and remove engine control module from E box right plenum chamber.

NOTE:

Engine Control Module (ECM) remains connected at wiring harness.
Disconnect connector - 4 - from connector strip at rear and set wiring harness aside.
Unclip suppressor - 5 - from bracket in E box right plenum chamber.
Remove all electrical harness connectors - 2 - from main fuse carrier - 1 -.

Fig 6: Releasing Clips And Removing One (Or Two) Engine Control Modules

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E box right plenum chamber, new version:

Release clips - arrows - and remove one (or two) engine control modules - 1 - and - 2 -.

NOTE:

The engine control modules remain connected at wiring harness.

Fig 7: Identifying Bolts

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Remove bolts - arrows -.

CAUTION: Pump-valve unit of heater (left in front of E box) heats up significantly during operation - danger of burns!

Remove cover of E-Box in right engine compartment.

Fig 8: Identifying Suppressor, Electrical Harness Connector, And Main Fuse Carrier

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Unclip suppressor - 5 - from bracket in E box.
Disconnect electrical harness connector - 4 - at rear of connector strip.
Remove electrical harness connectors - 2 - from main fuse carrier - 1 -.

NOTE:

Disregard - 3 -.

Fig 9: Releasing Clips And Removing Main Fuse Carrier From E Box Right Plenum Chamber

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All:

Release clips - arrows - and remove main fuse carrier - 1 - from E box right plenum chamber.

Fig 10: Releasing Locking Mechanisms And Pulling Secondary Relay Carrier In E Box Right Plenum Chamber Off Upward

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Release locking mechanisms - arrows - and pull secondary relay carrier in E box right plenum chamber off upward.

Fig 11: Removing Nuts On E Box Right Plenum Chamber

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Remove nuts - arrows - on E box right plenum chamber - 1 -.

Fig 12: Using Pry Lever 80 - 200 To Remove Instrument Panel Central Tube

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Lay wires at E box right plenum chamber aside using pry lever 80 - 200.

NOTE:

If necessary, use silicon-free spray lubricant to facilitate removal.
Remove E box right plenum chamber.

Installing

Installation is performed in reverse order of removal, noting the following:

When attaching cover for E box right plenum chamber, make sure cover is engaged correctly in mounts and no electrical wires are jammed.
Connect battery. Required actions Battery, disconnecting and connecting .
Adjust wiper arms → Wiper arms, adjusting .

Tightening torques

Component	Nm
E-box right plenum chamber to body	4
Electrical wires to main fuse carrier	9
B+ wire to main fuse carrier	20
Cover to E box right plenum chamber	4
Cowl grille to blower box	2.7