Installation

1. Install new O-rings in place on the two pipe connections and install the heat exchanger in place.
2. Clean the heat exchanger cover using washing gasoline and apply (10) 81 52 381, or equivalent in the groove. Install the cover using a new gasket. Tighten the bolts to 20 Nm (15 ft. lbs.) in a circular sequence, starting in the middle.
3. Install the two securing bolts for the heat exchanger. Connect the oil lines, but do not tighten the screws.





4. Install the bolt for the check valve bracket and fix the fastening between the oil lines.
5. Raise the car and install the oil lines to the cylinder block. Torque to 30 Nm (22 ft. lbs.).
6. Install the oil filter. Torque to 10 Nm (7.4 ft. lbs.).
7. Install the crankshaft position sensor. Lower the car.
8. Screw the oil lines to the heat exchanger and torque to 30 Nm (22 ft. lbs.).
9. Install the coolant bridge, using (10) 74 96 284, or equivalent on the bolts and torque to 30 Nm (22 ft. lbs.).
10. Apply acid-free Vaseline to the lower intake manifold and install it. See illustration for order. Lock the bolts using (10) 74 96 268, or equivalent and torque to 20 Nm (15 ft. lbs.).
11. Install the center intake manifold with fuel rail. Lock the bolts using (10) 74 96 268, or equivalent and torque to 20 Nm (15 ft. lbs.).





12. Connect the fuel lines.
13. Place the intake manifold in position and connect the Traction Control System (TCS) throttle body.
14. Tighten the intake manifold bolts to 20 Nm (15 ft. lbs.).
15. Connect the crankcase ventilation hose to the intake manifold, reposition the wiring harness conduit under the throttle body and connect the throttle position sensor and the ignition coil.
16. Connect the vacuum hoses to the intake manifold and connect the throttle body preheater hoses.
17. Connect the Idle Air Control (IAC) valve and the hose to the fuel pressure regulator.





18. Align the inlet pipes with the resonator and connect the vacuum hoses and the wiring harness. Connect the intake pipes to the intake manifold and the resonator to the mass air flow sensor.





19. Install the throttle control bracket and fasten the control rod, the throttle cable and the cruise control cable. Adjust the kick-down cable and the throttle cable.
20. Install the engine covers and raise the car.
21. Check that the radiator drain plug is properly installed and install the center air shield. Lower the car.
22. Reconnect the negative cable to the battery. Remove the covers protecting the wings.
23. Top up with coolant and check the system for leaks.
24. Check other oil and fluid levels and top up if necessary. Check that the engine compartment is clean.

WARNING: The coolant is very hot and under high pressure. When the pressure cap is opened there is a danger of scalding. Take great care.

25. Bleed the system as follows:
^ Fill the system up to the MAX level, install the pressure cap, start the engine and warm it up (preferably at different rpm) until the radiator fan starts.
^ Remove the pressure cap and refill to MAX. Install the pressure cap and run the engine at varying rpm until the radiator fan has started three more times.
^ Switch off the engine and top up to the MAX level, if necessary.
26. Test drive the car and check all functions.