Throttle Intake Elbow

Removal

1. WARNING: BEFORE PROCEEDING, IT IS ESSENTIAL THAT WARNING NOTES GIVEN IN SERVICE PRECAUTIONS ARE READ AND UNDERSTOOD.


Disconnect battery ground cable.
2. Remove air cleaner cover/intake assembly.
3. Remove throttle assembly.
4. Remove exhaust gas recirculation (EGR) valve where installed.





5. Release intake elbow from right-hand support bracket.
Release brake servo vacuum pipe and disconnect pipe.
Disconnect vacuum pipe.
Remove upper bolt.





6. Release intake elbow from left-hand support bracket.
Disconnect vacuum pipe.
Disconnect engine breather T-piece.
Remove upper bolt.
Loosen, but do not remove, lower two bolts.





7. Remove intake elbow from supercharger.
Release and pull back clips securing bypass hoses at charge air coolers.
Remove four bolts.
Remove hoses from charge air cooler stub pipes.
Remove assembly from vehicle.
Discard gasket.
Clean all mating faces.





8. Remove by-pass valve assembly from intake elbow.
Remove two bolts.
Remove by-pass assembly from elbow and discard O-ring.
9. Where necessary, remove blanking plate from intake elbow.
Remove bolts.
Discard gasket.
Clean all mating faces.

Installation
1. Where necessary, install blanking plate to intake elbow.
Install new gasket.
Install bolts (18 - 24 Nm).





2. Install by-pass valve assembly to intake elbow.
Install new O-ring and lubricate with petroleum jelly.
Install bolts.





3. Install intake elbow to supercharger.
Install two bolts to intake elbow and install new gasket.
Position intake elbow assembly with by-pass hoses located on charge air cooler stub pipes.
Install and tighten four bolts.
Position hose securing clips.





4. Install left-hand support bracket to intake elbow and re-connect pipework.
Install bolt.
Fully tighten two bolts.
Connect breather/purge pipe T-piece to intake elbow.
Connect vacuum pipe to intake elbow.





5. Install right-hand support bracket to intake elbow.
Install bolt.
6. Install exhaust gas re-circulation valve (EGR) if applicable.
7. Install throttle assembly.
8. Install air cleaner cover/intake assembly.
9. Reconnect battery ground cable.