Page 1137 of 2490
Intake Air Distribution and Filtering - Throt
tle Body Elbow4.0L NA V8 -
AJ27/3.2L NA V8 - AJ26
Re
moval and Installation
Remov
al
S
pecial Tool(s)
Re
lease tool - quick fit
310-044 (JD 182)
R
elease tool 5 /16 - quick fit
310-054 (JD 203)
1. WARNING: BEFORE PROCEEDING, IT IS ESSENTIAL THAT
THE WARNING NOTES GIVEN IN SECTION 100-00 (UNDER THE
HEADING 'SAFETY PRECAUTIONS') ARE READ AND
UNDERSTOOD.
Disconnect battery ground cable (IMPORTANT, see SRO
86.15.19 for further information).
2. D
epressurize fuel sy
stem; refer to 19.50.02
3. Remove air cleaner cover / intake assembly; refer to 19.10.30.
4. Remove throttle body; refer to 19.70.04.
5. R
elease intake elbow from right-hand support bracket.
Re
lease brake servo vacuum pi
pe and disconnect pipe.
1. Disconnect vacuum pipe.
2. Remove bolt.
6. Release intake elbow from le ft-hand support bracket.
1. Disconnect vacuum pipe.
2. Disconnect engine breather T-piece.
3. Remove bolt.
4. Loosen, but do not remove two bolts.
Page 1138 of 2490
7. Re
move engine covers
8. Disc onne
ct electrical connector from each fuel injector.
9. Disc
onnect fuel feed hose.
1. Use special tool 310-044 (JD 182).
10. Disconnect fuel return hose.
1. Use special tool 310-054 (JD 203).
Page 1139 of 2490
11
.
Remove intake manifold.
1. Remove ten bolts.
2. Remove intake manifold
12
.
Discard eight seals from intake manifold ports.
13
.
Remove throttle intake elbow from intake manifold.
1. Remove seven bolts.
2. Remove elbow.
3. Remove seal.
14. Where necessary, remove blanki ng plate from intake elbow.
Re
move bolts.
Di
scard gasket.
Cle
an all mating faces.
Page 1140 of 2490
In
stallation
15.
Cle
an manifold and mating faces on cylinder heads.
1. Where necessary, install blanking plate to intake elbow.
Inst al
l new gasket.
Inst
al
l bolts (18-24Nm).
2. Inst al
l intake elbow to intake manifold.
1. Install new seal.
2. Install seven bolts.
3. Install new seals to the eight intake manifold ports. Ensure the
seals are fully seated.
4. Inst al
l intake manifold.
1. Install ten bolts.
5. Connect fuel feed hose to fuel rail feed pipe. Ensure hose is
fully installed.
6. Connect fuel return hose to fuel rail return pipe. Ensure hose is
fully installed.
7. Con n
ect electrical connectors to fuel injectors.
8. Install left-hand support brac ket to intake elbow and re-
connect pipework.
1. Install bolt.
Page 1141 of 2490
2.
Tighten two bolts.
3. Connect breather/p urge pipe T-piece.
4. Connect vacuum pipe.
9. Install righ
t-hand support
bracket to intake elbow.
1. Install bolt.
2. Connect vacuum pipe.
10. Install throttle assemb ly; refer to 19.70.04.
11. Install air cleaner cover / intake assembly; re fer to 19.10.30.
12. Install engine covers.
13. Reconnect battery ground cable (IMPORTANT, see SRO
86.15.15 for further information).
Page 1142 of 2490

Intake Air Distribution and Filtering - Throttle B
ody Elbow4.0L SC V8 -
AJ26
Re mo
val and Installation
Remova
l
1.
WARNING: BE
FORE PROCEEDING, IT IS ESSENTIAL THAT
WARNING NOTES GIVEN IN SECTION 100-00 (UNDER HEADING
'SAFETY PRECAUTIONS') AR E READ AND UNDERSTOOD.
Disconnect battery ground cable (IMPORTANT, see SRO
86.15.19 for further information).
2. Re
move air cleaner cover / inta
ke assembly; refer 19.10.30.
3. Remove throttle assemb ly; refer to 19.70.04.
4. Remove exhaust gas recirculation (EGR) valve where installed;
refer 17.45.01.
5. Re
lease intake elbow from right-hand support bracket.
Re
lea
se brake servo vacuum pi
pe and disconnect pipe.
1. Disconnect vacuum pipe.
2. Remove upper bolt.
6. Relea
se intake elbow from le
ft-hand support bracket.
1. Disconnect vacuum pipe.
2. Disconnect engine breather T-piece.
3. Remove upper bolt.
4. Loosen, but do not remove, lower two bolts.
7. Re
move intake elbow from supercharger.
1. Release and pull back cl ips securing bypass hoses
at charge air coolers.
2. Remove four bolts.
3. Remove hoses from charge air cooler stub pipes.
Re move as
sembly from vehicle.
4. Discard gasket.
Cle a
n all mating faces.
8. Remove by-pass valve assembly from intake elbow.
Page 1143 of 2490
I
nstallation
1.
Remove two bolts.
Re
move by-pass assembly from
elbow and discard O-ring.
9. Where necessary, remove blanki ng plate from intake elbow.
Re
move bolts.
Di
scard gasket.
Cle
an all mating faces.
1. Where necessary, install blanking plate to intake elbow.
Inst
all new gasket.
Inst
all bolts (18-24Nm).
2. Inst
all by-pass valve assembly to intake elbow.
Inst
all new O-ring and lubricate with petroleum jelly.
1. Install bolts.
3. Install
intake elbow to supercharger.
1. Install two bolts to intake elbow and install new gasket.
2. Position intake elbow assembly with by-pass hoses located on charge air cooler stub pipes.
3. Install and tighten four bolts .
4. Position hose securing clips.
4. Install left-hand support brac ket to intake elbow and re-
connect pipework.
1. Install bolt.
Page 1144 of 2490
2.
Fully tighten two bolts.
3. Connect breather/purge pipe T-piece to intake elbow.
4. Connect vacuum pipe to intake elbow.
5. Install right-hand support brac
ket to intake elbow.
1. Install bolt.
6. Install exhaust gas re-circulation valve (EGR) if applicable;
refer to 17.45.01.
7. Install throttle assemb ly; refer to 19.70.04.
8. Install air cleaner cover / intake assembly; refer to 19.10.30.
9. Reconnect battery ground cable (IMPORTANT, see SRO
86.15.15 for further information).