Cylinder Head
Intake Plenum, Remove and Install
Remove wiper motor cover.
Remove exhaust gas recirculation corrugated pipe (3).
Pull wiring harness plug (2) off exhaust gas recirculation valve.
Remove exhaust gas recirculation valve adapter holder (4).
Remove accelerator actuation Bowden cable (5) and cruise control Bowden cable (1).
Disconnect coolant hose (8) from compensation tank to throttle body at throttle body - collect coolant.
Remove resonance pipes from intake plenum - 2 fastening clamps (7).
Detach wiring harness plug (6) from throttle valve potentiometer.
Remove idle speed adjuster - see operation "Idle Speed Adjuster, Remove and Install".
Detach brake servo hose on intake plenum.
Remove engine vent hoses (1) and vacuum hoses (2) from engine vent adapter.
Pull wiring harness plug (3) and vacuum hose (4) off solenoid valve for intake plenum switchover valve.
Remove retaining bolts (arrows).
Remove intake plenum from intake bridge, and rear coolant hose from throttle body.
Remove intake plenum and seal rings.
Fit 6 new seal rings to intake bridge - ensure correct fit.
Install intake plenum on intake bridge - ensure correct fit - 20 Nm.
Fit rear coolant hose to throttle body.
Fit engine vent hoses and vacuum hoses to engine vent adapter.
Fit wiring harness plug and vacuum hose to solenoid valve for intake plenum switchover valve.
Fit brake servo hose to intake plenum.
Install idle speed adjuster - see operation "Idle Speed Adjuster, Remove and Install".
Fit wiring harness plug to throttle valve potentiometer.
Fit resonance pipes to intake plenum - ensure correct fit.
Connect coolant hose from compensation tank to throttle body at throttle body.
Install accelerator actuation Bowden cable and cruise control Bowden cable.
Install exhaust gas recirculation valve adapter holder - 20 Nm.
Connect wiring harness plug to exhaust gas recirculation valve.
Apply assembly paste (white) to thread and install exhaust gas recirculation corrugated pipe - 25 Nm.
Install wiper motor cover.
Fill up cooling system - see operation "Cooling System, Fill and Bleed" and "Cooling System, Check for Leaks".