Installing the retaining bridge

Check 

• Check if the foam seal on retaining bridge (1) in area (2) is damaged, porous, loose or present.

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Result 

» Foam seal (2) is damaged or porous or loose.

Measure

• Replace the foam seal (2).

Parts:  foam

Measure

• Clean any foam seal residue or adhesive residue on the bonding surface in area (2) with cleaning agent R2.

Parts:  Cleaning agent

Measure

• Bond foam seal (2).

Result 

» Foam seal (2) is not installed.

Measure

• Retrofit foam seal (2).

Parts:  foam

Measure

• Clean the bonding surface in area (2) with cleaning agent R2.

Parts:  Cleaning agent

Measure

• Bond the foam with an adhesive.

• Clip wiring harness mounting (1) into the retaining bridge.

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• Clip wiring harness mounting (1) into the retaining bridge.

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• Feed the connector (2) of the Lambda oxygen sensor through.
• Connect and lock the engine ventilation line to the retaining clip in the region of (1).

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• Connect connectors (1) and lock.

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• Clip in the cable from the Lambda oxygen sensor on the holder (1).

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• Clip wiring harness mounting (1) into the retaining bridge.

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• Feed the connector (2) of the Lambda oxygen sensor through.
• Connect and lock the engine ventilation line to the retaining clip in the region of (1).

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• Connect connectors (1) and lock.

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• Connect connectors (1) and lock.

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• Clip in the cable from the Lambda oxygen sensor on the holder (1).

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• Connect connectors (1) and lock.

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• Install bellows (2).
• Tighten hose clamp (1).
  TIGHTENING TORQUE SPECIFICATIONS
  
  

  Hose clamp
  Hose clamp	Tightening torque	3 Nm

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• Connect and lock the engine ventilation line to the retaining clip in the region of (1).

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• Clip in the cable from the Lambda oxygen sensor on the holder (1).

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• Clip in the connector (2) downwards in the heat shield.
• Clip the transmission wiring harness on to the bracket (1).

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• Tighten down screws (1).
  TIGHTENING TORQUE SPECIFICATIONS
  
  

  Support bridge
  M6x16 screw	Tightening torque	10 Nm

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• Clip in the wiring harness from the attachment points (2).
• Working downwards, clip in the engine ventilation line (1).

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• Feed in and install coolant expansion tank (2).
• Tighten down screws (1).
  TIGHTENING TORQUE SPECIFICATIONS
  
  

  Coolant reservoir
  M6x20 screw	Tightening torque	11 Nm

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• Connect the wiring harness mounting to the snap-in lug (1) and lock it.

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• Tighten down screws (1).
  TIGHTENING TORQUE SPECIFICATIONS
  
  

  Coolant reservoir
  M6x20 screw	Tightening torque	11 Nm

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• Clip in the coolant line to the bracket in the region (2).
• Connect the coolant line (1) to the coolant expansion tank (2) and lock it.

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• Connect the coolant line (1) to the coolant expansion tank (2) and lock it.

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• Connect the coolant line (1) to the coolant expansion tank (2) and lock it.

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• Use clamping pliers to remove the coolant hoses (1) from the coolant expansion tank (2).

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• Connect connectors (1) and lock.
• Clip the wiring harness into the wiring harness mounting (1).

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• Close the sealing cap (1) of the coolant expansion tank.

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  Installing the control unit bracket for cylinders 5 to 8 

  NOTE: RISK OF DAMAGE 
  Electrostatic discharge. 
  Damage to or destruction of electrical components. 

  • Leave the electrical components in their original packaging until they are being installed. Only use the original packaging for returning the product. Always package removed components straight away.
  • Read and comply with user information on using the associated special tool 12 7 060.
  • Only tap the housings of electrical components. Do not tap pins or multi-pin connectors directly.
  • Wear electrically conductive clothing and antistatic shoes (with ESD symbol).
  • For additional information see: NOTES ON ESD PROTECTION (ELECTRO STATIC DISCHARGE) .
  NOTE: TECHNICAL INFORMATION 
  Follow instructions for removing and installing control units.
  For additional information see: INSTRUCTIONS FOR REMOVAL AND REPLACEMENT OF CONTROL UNITS .
  NOTE: TECHNICAL INFORMATION 
  If control units are disconnected, fault memory entries and functional limitations may occur.
  The fault memory entries must be read out and, if necessary, deleted.
• Guide and install control unit bracket (2) with the DME control unit into holder (3).
• Tighten down screws (1).
  TIGHTENING TORQUE SPECIFICATIONS
  
  

  Control unit holder
  Hexagon screw	Tightening torque	8 Nm

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• Fasten all the clamps (2).
• Connect all connectors (1) and lock.

  The connectors (1) must engage audibly.

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  Installing the cover of the left DME control unit 

• Feed in the cover (1) in the guides and install it.

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  Installing acoustic cover 

  NOTE: RISK OF DAMAGE 
  Damage to the acoustic cover/design cover. 
  Jerky movements during disassembly and application of excessive force during installation may result in breakage of the acoustic cover/design cover. 

  • Disassemble or mount the acoustic cover/design cover carefully.
  • Disassemble or mount snap-lock couplings of the ball pivots one after the other.
  • Disassemble or mount the acoustic cover/design cover only at temperatures > 20°C.
  • Use only distilled water as an auxiliary material during installation, no lubricants.
• Check the rubber mount (1) for a correct seat of the acoustic cover.

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• Install the acoustic cover (1) and fasten it in the rubber mounts (marks).

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• Version with clip: 

  Clip in the tank vent line (2) into the clamp (1).

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  Fill and vent the high-temperature coolant circuit 

  NOTE: TECHNICAL INFORMATION 
  It is mandatory  to fill the cooling system before bleeding.
  Fill both  the circuits for high and low-temperature coolant circuits.

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