Page 1041 of 2490

1.
Install
fuel injector(s).
1. Install new O-rings, lubricated with petroleum jelly, to
fuel injector.
2. Install fuel in jector into fuel rail. Press firmly until it is
felt to click into place.
3. Hold injector firmly down and fit injector securing clip
in the correct orientation.
2. Conne
ct fuel injector harness.
1. Reposition harness.
2. Tighten nuts which secure harness to camshaft cover.
3. Re-connect injectors.
3. Install charge air c ooler; refer to 18.50.18 and / or 18.50.19.
4. Install supercharger asse mbly; refer to 18.50.15.
5. Install supercharger driv e belt; refer to 18.50.08.
6. Install coolant outlet pi pe; refer to 26.31.08.
7. Install throttle induction elbow; refer to 19.70.28.
8. Install exhaust gas re-circulation valve (EGR) if applicable;
refer to 17.45.01.
9. Install throttle body ; refer to 19.70.04.
10. Install supercharger outlet duct; refer to 18.50.16.
11. Install air cleaner cover / intake assembly; re fer to 19.10.30.
12. Refill cooling system; refer to (SC) 26.10.01 .
13. Reconnect battery ground cable (IMPORTANT, see SRO
86.15.15 for further information).
Page 1042 of 2490
Fuel Char
ging and Controls - Throttle Body
Re
mo
val and Installation
Remov
a
l
• C
A
UTIONS:
When the throttle body is being replaced by a unit with the part number suffix ' BA', and carrying a sticker such as the
illustration below, then the usual cleaning procedure is NOT to be carried out. These thro ttle bodies have a molykote
coating which will be damaged by normal cleaning procedures. Refer to the latest service action s for further information.
This process assumes the use of the original throttle ca ble. The cable setting procedure in this instance is NOT
appropriate for a new cable; see 19.20.06.
1. Disc onne
ct battery ground cable (IMPORTANT, see SRO
86.15.19 for further information).
2. Remove air cleaner cover / in take assembly; refer 19.10.30
3. Disc
onnect connectors and vacuum pipe.
4. Ro
tate throttle quadrant to allow disconnection of inner cable.
5. NOTE: Do not disturb adjusting nut
Release throttle cable locking nut and displace outer cable from
Page 1043 of 2490
the
abutment bracket.
6. R
emove coolant hoses.
Inst
all suitable blanking plugs.
7. Re
lease connector from bracket
under LH side of assembly.
8. R
emove throttle body to indu
ction elbow securing bolts.
9. Remove throttle body from induction elbow.
1. Remove throttle body.
2. Discard gasket.
Cle
an mating faces.
Page 1044 of 2490
In
stallation
Bl
ank off inlet tract to prevent ingress of foreign matter.
10 . R
emove throttle cable and intake duct brackets.
1. Instal
l throttle cable an
d intake duct brackets.
2. Instal
l throttle.
Inst
al
l new gasket.
3. Install connector.
Page 1045 of 2490
4. Inst
all coolant hoses.
5. R
eposition outer cable
to abutment bracket.
Install but do not tigh
ten adjusting nut.
6. CAUTI
ON: Under no circumst
ances should quadrant be
held clear of throttle stop by cable tension.
• NOTE: Make sure ther e is neither tension nor slack in the cable.
Install throttle cable.
Tigh
ten locknut without altering setting or introducing
twist into the cable outer.
7. Connect conn
ectors and vacuum pipe.
Page 1046 of 2490
8. Wh ere appropri
ate check kick
down setting is within
specification and reset if requ ired as detailed from step 6
(Installation).
PDU use
rs see 44.15.38
9. Conne ct
scantool.
R
e
ad 'Current Powertrain Data'.
D
i
splay PID 120F (pedal demand).
10 . NO
TE: Ensure that contact with switch does not result in
switch movement.
Push throttle pedal until light contact is made with kickdown
switch.
11. Spe
cified PID value = 3.66 to 3.76 volts (2F9 + or - A hex).
If
the value is outside these limits, proceed to step 9
(Installation).
If t he
value is within these limits, proceed to step 13
(Installation).
12. Pull carpet from around kickdown switch.
13. Disconnect kickdown switch flying lead connector (to avoid
cable twist as the switch is rotated).
Page 1047 of 2490
14
.
Adjust kickdown switch to th e value as defined in step 8
(Installation).
15. Reconnect kickdown flying lead connector and verify setting.
16. Install air cleaner cover / intake assembly; refer 19.10.30.
17. Check coolant level and top up if required.
18. Reconnect battery ground cable (IMPORTANT, see SRO
86.15.15 for further information).
Page 1048 of 2490
Fuel Charging and Controls - Throt
tle Body Gasket
Re
mo
val and Installation
Remov
a
l
Installation
1.
Re
move throttle body; refer to 19.70.04.
1. Installation is a reversal of the removal procedure.