Removal

1. Open the driver's door, or both doors if necessary, to allow the side windows to drop. Ensure that the doors remain open until after the battery has been disconnected.
2. Open the engine compartment and install paintwork protection sheets.
3. Carefully remove the engine covers, taking care not to damage the plastic fixings or the rubber inserts.





4. Depressurize the fuel system.
^ Ensure that the ignition is switched off and remove the valve cap from the fuel cross-over pipe. Place a cloth under the valve to collect any spillage.
^ Place a closed container, suitable for collecting fuel, adjacent to the vehicle. Remove the lid.





5. Connect the fuel injection pressure test equipment JD 209 (or other suitable type). Insert the drain/bleed tube into the fuel container. Follow the manufacturer's instructions and depressurize the fuel system.
6. Store the drained fuel safely and ensure that the lid is closed securely. Remove the equipment and discard the cloth from beneath the valve. refit the valve cap.





7. Disconnect the battery ground cable.





8. Disconnect the breather pipe from the A-bank valve cover.
(1) Disconnect the breather pipe from the stub pipe.
(2) Remove and discard the O-ring seal from the breather pipe.

9. Disconnect the air flow meter multi-plug.
10. Cut and remove the strap which secures the vacuum pipe to the induction elbow.





11. Disconnect the intake tube from the throttle body.
(1) Remove the two bolts which secure the intake tube to the throttle body.
(2) Disconnect the intake tube from the throttle body.





12. Disconnect the air cleaner cover.
(1) Remove the five clips which secure the air cleaner cover.





13. Remove the intake tube/air flow meter/air cleaner cover assembly.
(1) Remove the intake tube / air flow meter / air cleaner cover assembly.
(2) Remove and discard the rubber seal; air intake tube to throttle body.





14. Disconnect the multi-plugs from the throttle body.
(1) Disconnect the throttle body motor multi-plug.
(2) Disconnect the two potentiometer multi-plugs, one each side of the throttle.
(3) Disconnect the vacuum pipe elbow from the throttle actuator.





15. Disconnect the throttle inner cable.
^ Turn the throttle pulley to the fully open position.
^ Disconnect the throttle inner cable from the pulley.





16. Disconnect the throttle outer cable.
^ Remove the throttle cable adjusting nut from the outer cable.
^ Remove the cable from the adjustment bracket.





17. Disconnect the coolant hoses from the throttle body.
^ Release the clip which secures the coolant return hose and disconnect the hose.
^ Release the clip which secures the coolant feed hose and disconnect the hose.
^ Install blanking plugs to the hoses.





18. Disconnect the multi-plug, located on the bracket under the left side of the throttle body.





19. Remove the throttle body securing bolts.





20. Remove the throttle body.
(1) Remove the throttle body from the induction elbow.
(2) Remove and discard the throttle body gasket.





21. Release the induction elbow support; working from the right hand side.
(1) Disconnect the vacuum pipe from the center of the induction elbow.
(2) Remove the upper bolt from the induction elbow support bracket.





22. Release the induction elbow support; working from the left hand side.
(1) Disconnect the vacuum pipe from the front of the induction elbow.
(2) Disconnect the engine breather T-piece from the induction elbow.
(3) Remove the upper bolt from the induction elbow support bracket.
(4) Loosen, but do not remove, the lower two bolts at the induction elbow support bracket.





23. Disconnect the electrical connector from each fuel injector.





24. Disconnect the fuel feed hose.
^ Disconnect the fuel feed hose at the Quick Install connector, using special tool JD 182.





25. Disconnect the fuel return hose.
^ Disconnect the fuel return hose at the Quick Install connector, using special tool JD 203.





26. Remove the inlet manifold.
(1) Remove the ten bolts which secure the inlet manifold.
(2) Remove the inlet manifold





27. Remove and discard the eight seals from the inlet manifold ports.
28. If reinstalling the manifold at this point, clean the manifold and mating faces on the cylinder head. Clean all other parts and relevant mating faces.
29. The instructions which follow are relevant only if a new manifold is to be fitted.





30. Remove the fuel pressure regulator from the manifold.
(1) Remove the two bolts which secure the pressure regulator.
(2) Remove the pressure regulator.
(3) Remove and discard the regulator O-ring seal.





31. Remove the fuel feed pipe from the manifold.
(1) Remove the two bolts which secure the fuel feed pipe to the inlet manifold.
(2) Remove the fuel feed pipe.
(3) Remove and discard the pipe O-ring seal.





32. Remove the fuel cross over elbow from the inlet manifold.
(1) Remove the one bolt each side which secures the cross over elbow.
(2) Remove the elbow from the manifold.
(3) Remove and discard the O-ring seal.





33. Remove the fuel injectors.
(1) Remove the securing screws from each fuel injector.
(2) Remove the injector clamping plates.





34. Remove the injectors from the manifold; use special tool JD 231 if necessary.





35. Remove and discard the sixteen sealing rings from the injectors.





36. Remove the throttle induction elbow from the inlet manifold.
(1) Remove the seven bolts which secure the throttle induction elbow.
(2) Remove the elbow.
(3) Remove the induction elbow seal from the manifold.