Installing the intake plenum

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NOTE: RISK OF DAMAGE
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.

Replace seals (1).
Parts: Seals

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Clean contact surface (1).

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Feed in and position intake plenum (2).
Connect and lock coolant line (1).
The coolant line (1) must audibly engage.

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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 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).
The coolant line (1) must audibly engage.

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Tighten down screw (1).

TIGHTENING TORQUE SPECIFICATIONS

Intake plenum to support
M6x25	Tightening torque	8 Nm

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Tighten down screw (4).

TIGHTENING TORQUE SPECIFICATIONS

Intake plenum to support
M6x25	Tightening torque	8 Nm

Thread in and install coolant line (3).
Secure clamps (2).

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Connect and lock connector (1).
The connector (1) must engage audibly.
Connect and lock the connector (1).
The connector (1) must engage audibly.

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Check the sealing ring (1) for damage and replace the tank vent line if necessary.

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Insert and install the tank vent line (2).
The locks (1) must 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).
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.

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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 (2).
Secure the tank vent line (2) to the clamp (3).

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

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Insert and install the wiring harness section (1) for the injectors and ignition coils.
The locks (arrows) must engage audibly.

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Feed in and install wiring harness section (2) for sensor system 2 .
The locks (1) must engage audibly.

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Check the sealing ring (1) for damage and, if necessary, replace it.

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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

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 .