Installing the intake plenum

• Replace seals (1)  .

  Parts:  Seals

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• Clean contact surface (1)  .

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  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.
• Feed in the intake plenum (2)  and position it.
• Feed in and install the wiring harness section (1)  for sensor system 1  .

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• Position the intake plenum (A)  .
• Tighten the screws in the sequence (1)  to (7)  .
  NOTE: Tighten the screws in 360-degree increments.
  TIGHTENING TORQUE SPECIFICATIONS
  
  

  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 coolant line (1)  engages audibly.

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

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

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• Tighten down screw (1)  .
  TIGHTENING TORQUE SPECIFICATIONS
  
  

  Intake plenum to support
  M6X25	Tightening torque	8 Nm

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• Tighten down screw (4)  .
  TIGHTENING TORQUE SPECIFICATIONS
  
  

  Intake plenum to support
  M6X25	Tightening torque	8 Nm

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• Thread in and install coolant line (3)  .
• Secure clamps (2)  .
• Connect and lock the connector (1)  .
• Make sure the connector (1)  engages audibly.
• 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 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 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)  .
• Secure the tank vent line (2)  to the clamp (3)  .
• Tighten down screw (1)  .
  TIGHTENING TORQUE SPECIFICATIONS
  
  

  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)  .

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• Attach the wiring harness section (1)  for the injectors and the ignition coils to the cylinder head cover (2)  .

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

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• Check the sealing ring (1)  for damage and replace the sealing ring (1)  as needed.

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

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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 INSTALLING THE RESONATOR WITH THE TOP CLEAN AIR PIPE .
• Refer to INSTALLING INTAKE SILENCER HOUSING .
• Refer to CONNECTING ALL BATTERY GROUND LEADS .
• Refer to FILLING AND VENTING THE LOW-TEMPERATURE COOLANT CIRCUIT .
• Refer to INSTALLING THE UNDERBODY PROTECTION OF THE STEERING GEAR OR THE FRONT THRUST FIELD .
• Refer to INSTALLING THE FRONT UNDERBODY PROTECTION OR FRONT THRUST FIELD .
• Refer to INSTALLING ACOUSTIC COVER AT REAR .
• Refer to INSTALLING THE FRONT HOOD SEAL AT THE REAR .
• Refer to INSTALLING ACOUSTIC COVER .
• Refer to TAKING HOOD OUT OF THE SERVICE POSITION .