Page 719 of 2490
5. Store the drained fuel safely and ensure that the lid is closed
securely. Remove the equipmen t and discard the cloth from
beneath the valve. refit the valve cap.
6. Disconnect the batt ery ground cable.
Remove the battery cover.
7. Disconnect the breather pipe fro m the A-Bank camshaft cover.
1. Disconnect the breather pipe from the stub pipe.
2. Remove and discard the O-ring seal from the breather
pipe.
8. Disconnect the air fl ow meter multi-plug.
9. Cut and remove the strap which secures the vacuum pipe to
the induction elbow.
10. Disconnect the intake tube from the throttle body.
1. Remove the two bolts which secure the intake tube to the throttle body.
2. Disconnect the intake tube from the throttle body.
Page 720 of 2490
11. Disconnect the air cleaner cover.
1. Remove the five clips wh ich secure the air cleaner
cover.
12. Remove the intake tube / air flow meter / air cleaner cover
assembly.
1. Remove the intake tube / air flow meter / air cleaner
cover assembly.
2. Remove and discard the ru bber seal; air intake tube
to throttle body.
13. Disconnect the multi-plug s from the throttle body.
1. Disconnect the throttle body motor multi-plug.
2. Disconnect the two potentiometer multi-plugs, one each side of the throttle.
3. Disconnect the vacuum pi pe elbow from the throttle
actuator.
14. Disconnect the throttle inner cable.
Turn the throttle pulley to the fully open position.
Disconnect the throttle in ner cable from the pulley.
15. Disconnect the throttle outer cable.
Remove the throttle cable adjusting nut from the outer
cable.
Remove the cable from the adjustment bracket.
Page 721 of 2490
16. Disconnect the coolant hoses from the throttle body.
Release the clip which secures the coolant return hose and
disconnect the hose. Fit a blanking plug to the hose to
prevent water leakage.
Release the clip which secures the coolant feed hose and
disconnect the hose. Fit a blanking plug to the hose to
prevent water leakage.
17. Disconnect the multi-plug, located on the bracket under the
left side of th e throttle body.
18. Remove the throttle bo dy securing bolts.
19. Remove the throttle body.
1. Remove the throttle body from the induction elbow.
2. Remove and discard the throttle body gasket.
Page 723 of 2490
Installation
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.
1. Clean all parts and relevant mating faces.
2. Fit eight new seals to the inlet manifold ports.
Page 724 of 2490
3. Fit the inlet manifold to the engine.
1. Fit the inlet manifold.
2. Fit the ten bolts which secure the inlet manifold.
4. 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.
5. 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.
6. Reconnect the electrical connector to each fuel injector.
Page 725 of 2490
7. Refit the induction elbow support ; working from the left hand
side.
1. Fit the upper bolt to the induction elbow support
bracket.
2. Tighten the lower two bolts at the induction elbow support bracket.
3. Connect the engine breather T-piece to the induction elbow.
4. Connect the vacuum pipe to the front of the induction
elbow.
8. Fit the induction elbow support; working from the right hand
side.
1. Fit the upper bolt to the induction elbow support
bracket.
2. Reconnect the vacuum pi pe to the centre of the
induction elbow.
9. Fit the throttle body.
1. Fit a new gasket to the throttle body.
2. Position the throttle body to the induction elbow.
10. Fit the throttle body securing bolts.
Page 726 of 2490
11. Reconnect the multi-plug, located on the bracket under the
left side of th e throttle body.
12. 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.
13. 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
Tighten the locknut without altering the setting or
introducing twist into the cable outer
Check the kickdown setting us ing the PDU. For scan tool
procedure, refer to 303-14 , Throttle cable, Renew
14. 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.
Page 727 of 2490
3. Connect the vacuum pipe elbow to the throttle
actuator.
15. 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.
16. Reconnect the air cleaner cover.
1. Fit the five clips which secure the air cleaner cover.
17. 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.
18. Reconnect the air flow meter multi-plug.
19. Fit a new strap to secures the vacuum pipe to the induction
elbow.
20. Connect the breather pipe to the A-Bank camshaft cover.
1. Fit a new O-ring seal to the breather pipe.