Removing the intake plenum

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: TECHNICAL INFORMATION
Additional coolant can leakage. Make sure that no coolant enters the intake port of the cylinder head.

NOTE: TECHNICAL INFORMATION
Collect and dispose of emerging fluids. Observe country-specific waste disposal regulations.

Preliminary work

Refer to BRINGING FRONT COMPARTMENT LID IN THE SERVICE POSITION .
Refer to DEACTIVATING THE 48 V ELECTRICAL SYSTEM .
Refer to DISCONNECTING ALL BATTERY GROUND LEADS .
Refer to REMOVING THE SEAL FOR THE HOOD REAR .
Refer to REMOVING THE ACOUSTIC COVER .
Refer to REMOVING ACOUSTIC COVER AT REAR .
Refer to REMOVING THE DME CONTROL UNIT .
Refer to REMOVING THE INTEGRATED POWER SUPPLY MODULE (PDM) .
Refer to REMOVING THE CONTROL UNIT HOLDER .
Refer to REMOVING THE FRONT UNDERBODY PROTECTION .
Refer to REMOVING THRUST FIELD .
Refer to DRAINING THE COOLANT FROM THE LOW-TEMPERATURE COOLING SYSTEM .
Refer to CONNECTING THE COOLANT LINES FOR THE LOW-TEMPERATURE COOLANT CIRCUIT .
Refer to REMOVING TANK VENT VALVE .

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
Damage to wires when disconnecting connectors and plug connections.
Sheared wires can cause a short circuit.

Do not pull on wires when disconnecting connectors and plug connections.

NOTE: TECHNICAL INFORMATION
Additional coolant can leakage. Make sure that no coolant enters the intake port of the cylinder head.

NOTE: TECHNICAL INFORMATION
Collect and dispose of emerging fluids. Observe country-specific waste disposal regulations.

Loosen screw (1).
Feed out and remove the tank vent line (2).

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Unlock and release the plug connections (1).
Unlock the locks (2).
Guide tank ventilation line (3) out of clamp (4) and remove it.

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Unlock the locks (1).
Feed the tank ventilation line (2) out and set it aside.

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Unlock the locks (1).
Guide out the wiring harness section (2) for the sensor system 2 and set it aside.

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Loosen screws (1).
Feed out charge air line (2) and place to one side.

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Unlock plug connection (1) and disconnect.
Loosen clamp (2).
Thread off coolant line (3) and place to the side.

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Release cover (1).

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Release nut (1).
Pull the positive battery cable (2) out and set it aside.

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Loosen screw (1).
Loosen clamp (2).
Pull the positive battery cable (3) out and set it aside.

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Unlock the locks (arrows).
Feed out the wiring harness section (1) for the injectors and ignition coils and put to one side.

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Loosen clamp (1).
Pull the positive battery cable (2) out and set it aside.

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Unlock and release plug connection (1).

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Guide tank ventilation line (1) out of clamp (2) and place it aside.

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Feed out the wiring harness section (1) for the injectors and ignition coils from the cylinder head cover (2) and put to one side.

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Loosen screw (1).

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Unlock and loosen coolant line (1).
Catch and dispose of escaping coolant.

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Unlock and loosen coolant line (1).
Catch and dispose of escaping coolant.

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Unlock and loosen coolant line (1).
Catch and dispose of escaping coolant.

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

Fig 1: Intake Plenum Screws Loosening Sequence
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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.
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Slightly lift the intake plenum (1).
Collect and dispose of escaping coolant at the openings (2) on the intake plenum (1).
NOTE: TECHNICAL INFORMATION
Conduct the following operation with the assistance of a second person.
Loosen clamp (1).
Guide out the intake plenum (2) and remove it.

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Empty the remaining coolant (2) from the intake plenum (1).

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NOTE: TECHNICAL INFORMATION
The tension rod screws and mounting bolts from the connecting neck on the intake plenum are not allowed to be opened.
Do not release screws in the marked area on the intake plenum (1).

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