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24. Disconnect the fuel return hose.
1. Disconnect the fuel retu rn hose at the Quick Fit
connector, using special tool 310 - 054.
25. Remove the inlet manifold.
1. Remove the ten bolts which secure the inlet manifold.
2. Remove the inlet manifold
26. Remove and discard the eight se als from the inlet manifold
ports.
27. Remove the fuel pressure regulator from the manifold.
1. Remove the two bolts which secure the pressure regulator.
2. Remove the pressure regulator.
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3. Remove and discard the regulator O-ring seal.
28. 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.
29. 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.
30. Remove the fuel injectors.
1. Remove the securing scre ws from each fuel injector.
2. Remove the inject or clamping plates.
31. Remove the injectors from the ma nifold; use special tool 303
- 539 if necessary.
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Installation
32. Remove and discard the sixt een sealing rings from the
injectors.
33. 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.
1. Clean all parts and relevant mating faces.
2. Fit the fuel pressure regulator to the manifold.
1. Lubricate and fit a new O-ri ng seal to the regulator.
2. Fit the pressure regulator to the manifold.
3. Fit the two bolts which secu re the pressure regulator.
3. Fit the fuel feed pipe to the manifold.
1. Lubricate and fit a new O-ri ng seal to the feed pipe.
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2. Fit the feed pipe to the manifold.
3. Fit the two bolts which secure the feed pipe.
4. Fit the fuel cross over elbow to the inlet manifold.
1. Lubricate and fit new O-ri ng seals to the cross over
elbow.
2. Fit the cross over elbow to the manifold.
3. Fit the one bolt each side which secures the cross over elbow.
5. Fit the sealing rings to the fuel injectors.
1. Lubricate and fit the sixteen (two to each injector) new sealing rings.
6. Fit the fuel injectors to the intake manifold.
1. Locate the injectors into the manifold.
2. Position the injector clamping plates.
3. Fit the securing screws for each fuel injector.
7. Fit the throttle induction elbow to the inlet manifold.
1. Fit a new induction elbow seal to the manifold.
2. Fit the elbow.
3. Fit the seven bolts which secure the throttle induction
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elbow.
8. Refit the Manifold Assembly to the Engine, as follows.
9. Fit eight new seals to the inlet manifold ports.
10. Fit the inlet manifold to the engine.
1. Fit the inlet manifold.
2. Fit the ten bolts which secure the inlet manifold.
11. Connect the fuel feed hose.
1. Connect the fuel feed hose at the Quick Fit connector. Ensure that the hose is fully seated to the feed pipe.
12. Connect the fuel return hose.
1. Connect the fuel return hose at the Quick Fit
connector. Ensure th at the hose is fully seated to the
feed pipe.
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17. Fit the throttle body securing bolts.
18. Reconnect the multi-plug, located on the bracket under the
left side of th e throttle body.
19. Connect the coolant hoses to the throttle body.
Remove the blanking plugs from the hoses.
Connect the coolant feed hose and secure with the clip.
Connect the coolant return hose and secure with the clip.
20. CAUTION: Under no circumstances may the quadrant be
held clear of the throttle stop by cable tension
Refit the throttle cable and ensure that there is neither tension
nor slack in the cable
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Tighten the locknut without altering the setting or
introducing twist into the cable outer
Check the kickdown setting using the PDU. For scan tool
procedure, refer to 303-14 , Throttle cable, Renew
21. Reconnect the multi-plugs to the throttle body.
1. Connect the throttle body motor multi-plug.
2. Connect the two potentiometer multi-plugs, one each side of the throttle.
3. Connect the vacuum pipe elbow to the throttle
actuator.
22. Fit the intake tube / air flow meter / air cleaner cover
assembly.
1. Fit a new rubber seal; air in take tube to throttle body.
2. Fit the intake tube / air flow meter / air cleaner cover
assembly.
23. Reconnect the air cleaner cover.
1. Fit the five clips which secure the air cleaner cover.
24. Connect the intake tube to the throttle body.
1. Connect the intake tube to the throttle body.
2. Fit the two bolts which secure the intake tube to the throttle body.
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25. Reconnect the air flow meter multi-plug.
26. fit a new strap to secures the vacuum pipe to the induction
elbow.
27. Connect the breather pipe to the A-Bank camshaft cover.
1. Fit a new O-ring seal to the breather pipe.
2. Reconnect the breather pipe to the stub pipe.
28. Carefully refit the engine covers, taking care not to damage
the plastic fixings or the rubber inserts.
29. Connect the battery ground cabl e. Refit the battery cover.
Reset the clock and the radio information.
30. Check for leaks and that all pi pes are securely connected.
Remove the protection sheets, close the engine compartment,
luggage compartment and doors.