Intake Air Plenum: Service and Repair

Removal

1. Open the engine compartment and fit paintwork protection sheets.
2. Remove the battery cover.
(1) Disconnect the battery ground cable.

3. Depressurize The Fuel System As Described in Fuel Pressure Release. Fuel Pressure Release.

4. Remove the air cleaner cover/intake assembly.
5. Remove the throttle assembly.
6. Release the induction elbow from the right hand support bracket.
(1) Release the brake servo vacuum pipe and disconnect the pipe.




(2) Disconnect the vacuum pipe from the center of the induction elbow.
(3) Remove the upper bolt from the induction elbow support bracket.
7. Release the induction elbow from the left-hand support bracket.




(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.




8. Remove the engine covers




9. Disconnect the electrical connector from each fuel injector.
10. Disconnect the fuel feed hose.




(1) Disconnect the fuel feed hose at the Quick Fit connector, using special tool JD 182.
11. Disconnect the fuel return hose.




(1) Disconnect the fuel return hose at the Quick Fit connector, using special tool JD 203.
12. Remove the inlet manifold.




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




13. Remove and discard the eight seals from the inlet manifold ports.
14. 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 gasket from the manifold.
15. Clean the manifold and mating faces on the cylinder heads. Clean all other parts and relevant mating faces.

Installation




1. Fit the induction elbow to the inlet manifold.
(1) Fit a new gasket between the induction elbow and the inlet manifold.
(2) Fit and tighten the seven bolts securing the induction elbow to the inlet manifold.
2. Fit new seals to the eight inlet manifold pons. Ensure the seals are fully seated.
3. Fit the inlet manifold to the engine.




(1) Fit and tighten the ten bolts securing the inlet manifold to the cylinder heads.
4. Connect the fuel feed hose to the fuel rail feed pipe. Ensure that the hose is fully fitted.
5. Connect the fuel return hose to the fuel rail return pipe. Ensure that the hose is fully fitted.
6. Fit the harness connectors to the fuel injectors.
7. Fit the left-hand support bracket to the induction elbow and reconnect the pipework.




(1) Fit the support bracket upper securing bolt and tighten.
(2) Fully tighten the two support bracket lower Securing bolts.
(3) Reconnect the breather/purge pipe T-piece to the induction elbow.
(4) Reconnect the vacuum pipe to the induction elbow.
8. Fit the right-hand support bracket to the induction elbow.




(1) Fit the support bracket upper securing bolt and tighten.
(2) Reconnect the vacuum pipe to the induction elbow.
9. Fit the throttle assembly.
10. Fit the air cleaner cover/intake assembly.
11. Fit the engine covers.
12. Reconnect the battery.
13. Remove the paintwork protection sheets and close the engine cover.