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(or other sui
table type). Insert the drain / bleed tube
into the fuel
container. Follow the manufa cturer's instructions and
depressurise the fuel system.
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. Di
sconnect the batt
ery ground cable.
R
emove 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 706 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.
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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 711 of 2490
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.
Page 712 of 2490
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
Page 714 of 2490
13. Reconnect the electrical connector to each fuel injector.
14. 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.
15. 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.
16. Fit the throttle body.
1. Fit a new gasket to the throttle body.
2. Position the throttle body to the induction elbow.
Page 715 of 2490
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
Page 716 of 2490
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.