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 and position intake plenum (2).
- Connect and lock coolant line (1).
The coolant line (1) must audibly engage.
NOTE: TECHNICAL INFORMATION Additional coolant can leakage. Make sure that no coolant enters the intake port of the cylinder head. - Position intake plenum (A).
- Tighten the screws in the sequence (1) to (7) at 360 degree intervals.TIGHTENING TORQUES SPECIFICATION
Intake plenum to cylinder head M6 Tightening torque 10 Nm - Connect and lock coolant line (1).
The coolant line (1) must audibly engage.
- Tighten down screw (1).TIGHTENING TORQUES SPECIFICATION
Intake plenum to support M6X25 Tightening torque 8 Nm - Tighten down screw (4).TIGHTENING TORQUES SPECIFICATION
Intake plenum to support M6X25 Tightening torque 8 Nm - Thread in and install coolant line (3).
- Secure clamps (2).
- Connect and lock connector (1).
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 vent 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 vent 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 and lock connector (1).
The connector (1) must engage audibly.
- Check the sealing rings (1) for damage and replace the tank vent 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 TORQUES 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).
- Secure the wiring harness section (1) for the injectors and ignition coils on the cylinder head cover (2).
- Insert and install the wiring harness section (1) for the injectors and ignition coils.
The locks (arrows) must engage audibly.
- Feed in and install 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 TORQUES 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 INSTALLING ACOUSTIC COVER AT REAR .
- Refer to INSTALLING THE COWL UPPER PART .
- Refer to INSTALLING WINDSHIELD PANEL COVER .
- Refer to INSTALLING LEFT AND RIGHT WIPER ARM .
- Refer to INSTALLING THE REAR RIGHT ENGINE COMPARTMENT COVER .
- Refer to INSTALLING THE COVER OF THE ENGINE COMPARTMENT ON THE REAR LEFT .
- Refer to INSTALLING THE FRONT HOOD SEAL AT THE REAR .
- Refer to FILLING THE LOW-TEMPERATURE COOLING SYSTEM WITH THE VACUUM FILLING EQUIPMENT .
- Refer to RECONNECTING ALL BATTERY GROUND LEADS
- Refer to VENTING THE LOW-TEMPERATURE COOLING SYSTEM .
- Refer to INSTALLING THE COVER OF THE STEERING ASSEMBLY .
- Refer to INSTALLING THE CENTER UNDERBODY PROTECTION .
- Refer to INSTALLING THE FRONT UNDERBODY PROTECTION .
- Refer to INSTALLING ACOUSTIC COVER .
- Refer to TAKE HOOD OUT OF THE SERVICE POSITION .