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 the intake plenum (2) and position it.
- Connect and lock coolant line (1).
The coolant line (1) must engage audibly.
NOTE: TECHNICAL INFORMATION
Additional coolant can leakage. Make sure that no coolant enters the intake port of the cylinder head. - Position the intake plenum (A).
- Tighten the screws in the sequence (1) to (7) in 360 degree increments.TIGHTENING TORQUES SPECIFICATION
Intake plenum to cylinder head M6 Tightening torque 10 Nm - Connect and lock coolant line (1).
The coolant line (1) must engage audibly.
- 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 connector (1) and lock.
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 ventilation 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 ventilation 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 connector (1) and lock.
The connector (1) must engage audibly.
- Check the sealing rings (1) for damage and replace the tank ventilation 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).
- Attach the wiring harness section (1) for the injectors and the ignition coils on the cylinder head cover (2).
- Feed in and install the wiring harness section (1) for the injectors and the ignition coils.
The locks (arrows) must engage audibly.
- Feed in and install the 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 THE LOW-TEMPERATURE COOLANT EXPANSION TANK .
- Refer to FILLING THE LOW-TEMPERATURE COOLING SYSTEM WITH THE VACUUM FILLING EQUIPMENT .
- Refer to VENTING THE LOW-TEMPERATURE COOLING SYSTEM .
- Refer to CHECKING LOW-TEMPERATURE COOLING SYSTEM FOR WATERTIGHTNESS .
- Refer to INSTALLING THE COVER OF THE STEERING ASSEMBLY .
- Refer to INSTALLING THE STIFFENING PLATE .
- Refer to INSTALLING FRONT UNDERBODY PROTECTION .
- Refer to INSTALLING ACOUSTIC COVER AT REAR .
- Refer to INSTALLING ACOUSTIC COVER .
- Refer to TAKING HOOD OUT OF THE SERVICE POSITION .