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Intake Plenum, Remove and Install (X 25 XE, X 30
XE)
 Remove
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Disconnect ground cable from battery.
Detach idle speed adjuster hose (2) from air intake hose
connection.
Detach air intake hoses (1) from housing for resonance pipes
switchover valve and throttle body.
Remove retainer for accelerator Bowden cable and unclip Bowden
cable (3) from ball head.
If present: Remove retainer for cruise control Bowden cable and
remove cruise control Bowden cable (4) from ball head.
Detach Bowden cables from Bowden cable bracket and lay
aside.
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Detach coolant hoses (2) and (3) from throttle body –
collect coolant.
Detach wiring harness plug (1) from exhaust gas recirculation
valve.
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Detach wiring harness plug from throttle valve potentiometer
(3), idle speed adjuster (2) and solenoid valve for intake plenum
switchover valve (1).
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For vehicles up to MY '98: Disconnect wiring harness plug for
knock sensor (1) and remove cable bundle from exhaust gas
recirculation valve bracket.
Remove corrugated pipe (2) from exhaust gas recirculation valve
adapter – counterhold on screw-on port. Remove fastening bolt
(3) from exhaust gas recirculation valve adapter.
Detach brake servo vacuum line (4) from intake plenum –
counterhold on screw-on port.
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Detach vacuum hoses (1) and engine vent hoses (2) from engine
vent adapter.
Remove fastening bolts (3) from intake plenum and lay bracket
aside.
Remove fastening bolts for sealing cap from intake plenum.
Remove fastening bolts (4). Carefully pull intake plenum
upwards. Detach vacuum lines from solenoid valve for intake plenum
switchover valve and fuel pressure regulator.
Lay intake plenum aside – note seal rings.
Caution
Mask intake ducts – foreign objects can cause engine
damage.
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Remove
Remove vacuum line (2) from solenoid valve for intake plenum
switchover valve (1).
Remove vacuum line (3) from fuel pressure regulator.
Remove intake plenum and seal rings.
Install
Place six new seal rings (4) on intake bridge – ensure
installation position is correct.
Attach vacuum lines to solenoid valve for intake plenum
switchover valve and fuel pressure regulator.
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Note: The intake
bridge has two guide pins (arrows) for locking the intake
plenum.
Attach intake plenum (1) to intake bridge – ensure correct
seating – tightening torque 8 Nm / 6 lbf. ft.
Attach fastening bolts for sealing caps to intake plenum.
Attach brackets to intake plenum – 3 off.
Attach vacuum hoses and engine vent hoses to engine vent
adapter.
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Attach brake servo vacuum line to intake plenum –
counterhold on screw-on port.
Attach support to exhaust gas recirculation valve adapter
– tightening torque 20 Nm / 15 lbf. ft.
Coat the thread with mounting paste (white) and attach exhaust
gas recirculation corrugated pipe to exhaust gas recirculation
valve adapter – tightening torque 25 Nm / 18 lbf. ft.
For vehicles up to MY '98: Connect wiring harness plug for knock
sensor and cable bundle to exhaust gas recirculation bracket.
Attach wiring harness plug to exhaust gas recirculation valve,
throttle valve potentiometer, idle speed adjuster and solenoid
valve for intake plenum switchover valve.
Attach coolant hoses to throttle body.
If present: Attach cruise control Bowden cable to bracket.
Attach Bowden cable to ball head and secure.
Attach accelerator Bowden cable to bracket. Clip Bowden cable to
ball head and secure.
Attach air intake hoses to throttle body and housing for
resonance pipes switchover valve – ensure correct
seating.
Attach idle speed adjuster hose to air intake hose
connection.
Connect ground cable to battery.
Top up cooling system – see operations "Cooling System,
Top Up and Bleed" and "Cooling System, Check for Leaks".
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