Installing the intake plenum

CAUTION: Improper routing of the positive battery cable.
Risk of short circuits!

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
Improper routing of cables and wiring harnesses.
Trapped, crushed or damaged cables may cause short circuits and malfunctions.

NOTE: TECHNICAL INFORMATION
Make sure that the connections are locked correctly. The locks must engage audibly.

Replace seals (1).
Parts: Seals

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Clean contact surface (1).

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NOTE: TECHNICAL INFORMATION
Conduct the following operation with the assistance of a second person.
Feed in the intake plenum (2) and position it.
Secure the clamp (2).

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Feed in and install the intake plenum (1).
Make sure that the remaining coolant does not run out from the openings (2) of the intake plenum (1) on the starter generator.

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

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

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Insert the positive battery cable (2) and install it.
Secure the clamp (1).

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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 position the positive battery cable (3).
Secure the clamp (2).

Tighten down screw (1).

TIGHTENING TORQUE SPECIFICATIONS

Intake plenum to support
M6X25	Tightening torque	8 Nm

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WARNING: Incorrect screw connection of positive battery cable.
Risk of fire!

Tighten nut (1).

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TIGHTENING TORQUE SPECIFICATIONS

Positive battery cable to the starter motor generator
M8	Tightening torque	19 Nm

Insert and install the cover (1).

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Feed in and install the coolant lines (3).
Secure the clamp (2).
Connect connectors (1) and lock.
The connector (1) must engage audibly.

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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 ventilation 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 ventilation line (2) if necessary.

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Insert and install the tank vent line (2).

Tighten down screw (1).

TIGHTENING TORQUE SPECIFICATIONS

Tank vent line to intake plenum
Oval-head screw	Tightening torque	3 Nm

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Insert and install the tank vent line (1).
Secure the tank vent line (1) to the clamp (2).

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Feed in and install the wiring harness section (2) for 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) if necessary.

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

TIGHTENING TORQUE SPECIFICATIONS

Charge air line to throttle valve
M6x30	tightening torque	8 Nm

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Follow-up work