Installing the intake plenum

CAUTION: Improper routing of the positive battery cable .
Risk of short circuits!

Route the positive battery cable without abrasions and do not trap.

NOTE: RISK OF DAMAGE
Coolant leaking from the starter motor generator .
Damage and loss of function of the starter motor generator .

Cover the starter motor generator with suitable, watertight auxiliary materials.
Close off line connections with seal plugs.
If necessary: Rinse off the coolant leaking from starter motor generator with at least 1 l of water.

NOTE: RISK OF DAMAGE
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.

Replace seals (1) .

Parts: Seals

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Clean contact surface (1) .

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NOTE: TECHNICAL INFORMATION
Conduct the following operation with the assistance of a second person.
Feed in and position intake plenum (2) .
Secure the clamp (2) .

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Feed in and install the intake plenum (1) .
Ensure that no residual coolant comes out of the openings (2) of the intake plenum (1) on the starter motor generator.

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Tighten the screws on the intake plenum (A) in the sequence (1) to (7) .

NOTE: Tighten the bolts in 360 degree steps.

TIGHTENING TORQUE SPECIFICATION

Intake plenum to cylinder head
M6	Tightening torque	10 Nm

Fig 1: Intake Plenum Screws Tightening Sequence

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Connect and lock coolant line (1) .
Make sure that the cooling line (1) engages audibly.

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Connect and lock coolant line (1) .
Make sure that the cooling line (1) engages audibly.

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Connect and lock coolant line (1) .
Make sure that the cooling line (1) engages audibly.

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Tighten down screw (1) .

TIGHTENING TORQUE SPECIFICATION

Intake plenum to support
M6X25	Tightening torque	8 Nm

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Secure the wiring harness section (1) for the injectors and ignition coils on the cylinder head cover (2) .

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Insert the positive battery cable (2) and install it.
Secure the clamp (1) .

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Insert and install the wiring harness section (1) for the injectors and the ignition coils.
The locks (arrows) must engage audibly.

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Feed in and position the positive battery cable (3) .
Secure the clamp (2) .
Tighten down screw (1) .

TIGHTENING TORQUE SPECIFICATION

Intake plenum to support
M6X25	Tightening torque	8 Nm

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Insert the positive battery cable (2) and install it.
Tighten nut (1) .

TIGHTENING TORQUE SPECIFICATION

Positive battery cable to the starter motor generator
M8	Tightening torque	19 Nm

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Insert and install the cover (1) .

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Feed in and install the coolant lines (3) .
Secure the clamp (2) .
Connect connectors (1) and lock.

The connector (1) must engage audibly.

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Connect and lock the connector (1) .
Make sure the connector (1) engages audibly.

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Check the sealing ring (1) for damage and replace the tank vent line if necessary.

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Insert and install the tank vent line (2) .
Ensure that the locks (1) engage audibly.

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Check the sealing rings (1) for damage and replace the tank vent line (2) if necessary.

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Insert and install the tank vent line (3) .
Ensure that the locks (2) engage audibly.
Secure the tank vent line (3) to the clamp (4) .
Connect and lock the connector (1) .
Make sure the connector (1) engages audibly.

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Check the sealing rings (1) for damage and replace the tank vent line (2) if necessary.

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Insert and install the tank vent line (2) .

Tighten down screw (1) .

TIGHTENING TORQUE SPECIFICATION

Tank vent line to intake plenum
Oval-head screw	Tightening torque	3 Nm

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Insert and install the tank vent line (1) .
Secure the tank vent line (1) to the clamp (2) .

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Feed in and install wiring harness section (2) for sensor system 2.
Ensure that the locks (1) engage audibly.

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Check the sealing ring (1) for damage and replace the sealing ring (1) if necessary.

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Insert and install charge air line (2) .
Tighten the screws (1) .

TIGHTENING TORQUE SPECIFICATION

Charge air line to throttle valve
M6x30	tightening torque	8 Nm

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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 CONNECTING NEGATIVE BATTERY CABLE OF THE SYSTEM BATTERY .
Refer to ACTIVATING THE 48 V ELECTRICAL SYSTEM .
Refer to FILLING AND VENTING THE LOW-TEMPERATURE COOLANT CIRCUIT .
Refer to INSTALLING ACOUSTIC COVER AT REAR .
Refer to INSTALLING THE FRONT HOOD SEAL AT THE REAR .
Refer to INSTALLING ACOUSTIC COVER .
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 .
Refer to TAKING HOOD OUT OF THE SERVICE POSITION .