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.
- Replace seals (1).
Parts: Seals
- Clean contact surface (1).
- Feed in the intake plenum (2) and position it.
- Connect and lock coolant line (1).
The coolant line (1) must engage audibly.
NOTE: TECHNICAL INFORMATION
Additional coolant can leakage. Make sure that no coolant enters the intake port of the cylinder head. - Position the intake plenum (A).
- Tighten the screws in the sequence (1) to (7) in 360 degree increments.TIGHTENING TORQUE SPECIFICATION
Intake plenum to cylinder head M6 Tightening torque 10 Nm - Connect and lock coolant line (1).
The coolant line (1) must engage audibly.
- Tighten down screw (1).TIGHTENING TORQUE SPECIFICATION
Intake plenum to support M6X25 Tightening torque 8 Nm - Tighten down screw (4).TIGHTENING TORQUE SPECIFICATION
Intake plenum to support M6X25 Tightening torque 8 Nm - Thread in and install coolant line (3).
- Secure clamps (2).
- Connect connector (1) and lock.
The connector (1) must engage audibly.
- Connect and lock the connector (1).
The connector (1) must engage audibly.
- Check the sealing ring (1) for damage and replace the tank ventilation line if necessary.
- Insert and install the tank vent line (2).
The locks (1) must engage audibly.
- Check the sealing rings (1) for damage and replace the tank ventilation line (2) if necessary.
- Insert and install the tank vent line (3).
The locks (2) must engage audibly.
- Secure the tank vent line (3) to the clamp (4).
- Connect connector (1) and lock.
The connector (1) must engage audibly.
- Check the sealing rings (1) for damage and replace the tank ventilation line (2) if necessary.
- 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 - Insert and install the tank vent line (1).
- Secure the tank vent line (1) to the clamp (2).
- Attach the wiring harness section (1) for the injectors and the ignition coils on the cylinder head cover (2).
- 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 sensor system 2.
The locks (1) must engage audibly.
- Check the sealing ring (1) for damage and, if necessary, replace it.
- Insert and install charge air line (2).
- Tighten down screws (1).TIGHTENING TORQUE SPECIFICATION
Charge air line to throttle valve M6x30 tightening torque 8 Nm
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 ALL BATTERY GROUND LEADS .
- Refer to FILLING AND VENTING THE LOW-TEMPERATURE COOLANT CIRCUIT .
- Refer to INSTALLING ACOUSTIC COVER AT REAR .
- Refer to INSTALLING THE REAR HOOD SEAL .
- Refer to INSTALLING ACOUSTIC COVER .
- Refer to INSTALLING THE STIFFENING PLATE .
- Refer to INSTALLING THE CENTER UNDERBODY PROTECTION .
- Refer to INSTALLING FRONT UNDERBODY PROTECTION .
- Refer to TAKING HOOD OUT OF THE SERVICE POSITION .