Installing the intake plenum
NOTE:
RISK OF DAMAGE
Improper routing of cables and wiring harnesses .
Trapped, crushed or damaged cables may cause short circuits and malfunctions .
Improper routing of cables and wiring harnesses .
Trapped, crushed or damaged cables may cause short circuits and malfunctions .
- Route all cables without abrasions, do not trap and crush.
NOTE:
TECHNICAL INFORMATION
Make sure that the connections are locked correctly. The locks must engage audibly.
Make sure that the connections are locked correctly. The locks must engage audibly.
Additional coolant can leakage. Make sure that no coolant enters the intake port of the cylinder head.
- Guide in and position intake plenum (A) on the cylinder head.
- Tighten the screws in order from (1) to (5) .
NOTE:
Tighten the screws in 360-degree increments.
TIGHTENING TORQUE SPECIFICATION
| Intake plenum to cylinder head | ||
| M6 | Tightening torque | 10 Nm |
- Connect and lock the coolant feed line (1) .
- Ensure that coolant feed line (1)
snaps in audibly.
- Tighten down screw (1) .
TIGHTENING TORQUE SPECIFICATION
| Intake plenum to support | ||
| M6X25 | Tightening torque | 8 Nm |
- Feed in and install the wiring harness section (1) for the injectors and the ignition coils.
The locks (arrows) must engage audibly.
- Feed in and install the wiring harness section (2) for the injectors and the ignition coils.
- Secure clamps (1)
.
- Guide in and install the wiring harness section (2) for sensor system 1.
- Secure clamps (1)
.
- Insert and install the tank vent line (1) .
- Secure the tank vent line (1)
to the clamp (2)
.
- Connect connectors (1) and lock.
- Make sure the connector (1) engages audibly.
- Tighten down screw (2)
.TIGHTENING TORQUE SPECIFICATION
Throttle body to holder M6X25 Tightening torque 8 Nm - Insert and install the coolant hose (2) .
- Fasten the clamping collar (1) with the special tool 0 495 794 (17 2 050) .
- Guide in and install the wiring harness section (3) for sensor system 2.
- Make sure that the locks (arrows) engage audibly.
- Insert and install the tank vent line (2) .
- Secure the tank vent line (2) to the clamp (3) .
- Tighten down screw (1)
.TIGHTENING TORQUE SPECIFICATION
Tank vent line to intake plenum Oval-head screw Tightening torque 3 Nm - Connect connectors (1)
and lock.
The connector (1) must engage audibly.
- Insert and install the tank vent line (1) .
The locks (arrows) must engage audibly.
- Insert and install the holder (2) .
- Ensure that lock (1)
snaps in audibly.
- Replace the seal (1)
.
Parts: Seal
- Insert and install charge air line (1) .
- Tighten screws (arrows).TIGHTENING TORQUE SPECIFICATION
Charge air line to throttle body M6 tightening torque 8 Nm - Connect connectors (1) and lock.
- Connect connectors (2) and lock.
- Make sure that the connector (1) and (2) engages audibly.
- Secure clamps (3) .
Follow-up work
- Refer to INSTALLING THE TANK VENT VALVE .
- Refer to INSTALLING CONTROL UNIT BRACKET .
- Refer to INSTALLING THE INTEGRATED POWER SUPPLY MODULE (PDM) .
- Refer to INSTALLING THE DME CONTROL UNIT .
- Refer to FILLING THE LOW-TEMPERATURE COOLING SYSTEM WITH THE VACUUM FILLING EQUIPMENT .
- Refer to CONNECTING NEGATIVE BATTERY CABLE OF THE SYSTEM BATTERY .
- Refer to VENTING THE LOW-TEMPERATURE COOLING SYSTEM .
- Refer to INSTALLING ACOUSTIC COVER AT REAR .
- Refer to INSTALLING ACOUSTIC COVER .
- Refer to INSTALLING THE FRONT HOOD SEAL AT THE REAR .
- Refer to IF INSTALLED: INSTALL UNDERBODY PROTECTION FOR THE STEERING .
- Refer to INSTALLING THE UNDERBODY PROTECTION OF THE STEERING GEAR .
- Refer to INSTALLING FRONT UNDERBODY PROTECTION .