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.

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

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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 the intake plenum (A).
Tighten the screws in the sequence (1) to (7) in 360 degree increments.

Fig 1: Intake Plenum Screws Tightening Sequence
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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.

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Tighten down screw (1).

TIGHTENING TORQUES SPECIFICATION

Intake plenum to support
M6X25	Tightening torque	8 Nm

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Tighten down screw (4).

TIGHTENING TORQUES SPECIFICATION

Intake plenum to support
M6X25	Tightening torque	8 Nm

Thread in and install coolant line (3).

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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.

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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).
The locks (1) must engage 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 (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.

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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).
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

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

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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 install the 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 TORQUES SPECIFICATION

Charge air line to throttle valve
M6x30	tightening torque	8 Nm

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Follow-up work