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)
.NOTE: TECHNICAL INFORMATION
Additional coolant can leakage. Make sure that no coolant enters the intake port of the cylinder head. - Guide in and position intake plenum (A) on the cylinder head.
- Tighten the screws in order from (1)
to (5)
.NOTE: Tighten the screws in 360-degree increments.TIGHTENING TORQUES SPECIFICATION
Intake plenum to cylinder head M6 Tightening torque 10 Nm - Connect and lock the coolant feed line (1) .
- Ensure that coolant feed line (1)
snaps in audibly.
- Tighten down screw (1)
.TIGHTENING TORQUES SPECIFICATION
Intake plenum to support M6X25 Tightening torque 8 Nm - 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 the injectors and the ignition coils.
- Secure clamps (1)
.
- Guide in and install the wiring harness section (2) for sensor system 1.
- Secure clamps (1)
.
- Insert and install the tank vent line (1) .
- Secure the tank vent line (1)
to the clamp (2)
.
- Connect connectors (1) and lock.
- Make sure the connector (1) engages audibly.
- Tighten down screw (2)
.TIGHTENING TORQUES SPECIFICATION
Throttle body to holder M6X25 Tightening torque 8 Nm - Insert and install the coolant hose (2) .
- Fasten the clamping collar (1) with the special tool 0 495 794 (17 2 050) .
- Guide in and install the wiring harness section (3) for sensor system 2.
- Make sure that the locks (arrows) engage audibly.
- 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 - Connect connectors (1)
and lock.
The connector (1) must engage audibly.
- Insert and install the tank vent line (1)
.
The locks (arrows) must engage audibly.
- Insert and install the holder (2) .
- Make sure that the lock (1)
snaps in audibly.
- Replace the seal (1)
.
Parts: Seal
- Insert and install charge air line (1) .
- Tighten screws (arrows).TIGHTENING TORQUES SPECIFICATION
Charge air line to throttle body M6 Tightening torque 8 Nm - Connect connectors (1) and lock.
- Connect connectors (2) and lock.
- Make sure that the connector (1) and (2) engages audibly.
- Secure clamps (3)
.
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 FILLING THE LOW-TEMPERATURE COOLING SYSTEM WITH THE VACUUM FILLING EQUIPMENT .
- Refer to ACTIVATING VEHICLE-SPECIFIC HIGH-VOLTAGE OR LOW-VOLTAGE VEHICLE ELECTRICAL SYSTEM .
- Refer to VENTING THE LOW-TEMPERATURE COOLING SYSTEM .
- Refer to INSTALLING ACOUSTIC COVER AT REAR .
- Refer to INSTALLING ACOUSTIC COVER .
- Refer to INSTALLING THE REAR HOOD SEAL .
- Refer to INSTALLING THE STIFFENING PLATE .
- Refer to INSTALLING UNDERBODY PROTECTION AT REAR .
- Refer to INSTALLING BOTTOM FRONT COVER FROM THE SIDE .
- Refer to INSTALLING FRONT UNDERBODY PROTECTION .