Page 1134 of 2490

Intake Air Distribution and Filtering - Thrott
le Body Elbow
Re
mo
val and Installation
Remov
a
l
1.
WARNING: B E
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 1135 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 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 1155 of 2490

T
he canisters are fixed to the underside of the vehicle either
directly or via semi-enclosed mounting brackets. Two fixing
bolts are used at the front of the canister(or bracket) and a single rear bolt supports the canister and the canister close
valve (CCV).
The vapour pipes to the canisters, other than the CCV, use multi-tang connectors which are push fitted and pulled out
without the use of tools.
The canister close valve has a stub pipe with 'O' ring seal wh ich is a simple push fit into the canister. A mounting bracket on
the canister close valve enables it to be secured to the underbody via the canister rear mounting bolt.
A hose connects the CCV to the bracket mounted adaptor into which the vent system air filter is screwed.
It
em
Par
t Number
De
scription
1—C
harcoal canister (righthand) in mounting bracket
2—Cani
ster close valve (showi
ng canister stub pipe)
3—Ai
r filter
4—Q
uick-fit vapour inlet connector
5—Cani
ster close valve electrical connector
Canister, CCV an
d Fittings
Page 1159 of 2490

T
he canisters are fixed to the underside of the vehicle either
directly or via semi-enclosed mounting brackets. Two fixing
bolts are used at the front of the canister(or bracket) and a single rear bolt supports the canister and the canister close
valve (CCV).
The vapour pipes to the canisters, other than the CCV, use multi-tang connectors which are push fitted and pulled out
without the use of tools.
The canister close valve has a stub pipe with 'O' ring seal wh ich is a simple push fit into the canister. A mounting bracket on
the canister close valve enables it to be secured to the underbody via the canister rear mounting bolt.
A hose connects the CCV to the bracket mounted adaptor into which the vent system air filter is screwed.
It
em
Par
t Number
De
scription
1—C
harcoal canister (righthand) in mounting bracket
2—Cani
ster close valve (showi
ng canister stub pipe)
3—Ai
r filter
4—Q
uick-fit vapour inlet connector
5—Cani
ster close valve electrical connector
Canister, CCV an
d Fittings
Page 1160 of 2490
Ite
m
Part
Number
Descr
iption
1—Fu
el tank pressure sensor (if applicable)
2—Engine m
anagement ECU
3—EVAP canister purge va
lve
4—EVAP ca
nister close valve (if applicable)
5—Engine
mana
gement fusebox - IGN supply
Circuit diagram
,
evaporative emissions systems
Page 1169 of 2490
Evaporative Emissions - Evaporative Emission Canister Purg
e Valve
Re
moval and Installation
Remov
al
Installation
1. O
pen the engine compartment and fit paintwork protection
sheets.
2. Disconnect the battery.
R
emove the battery cover.
Di
sconnect the battery ground (negative) cable.
3. Di
sconnect the purge valve harness connector.
4. R
emove the two securing nuts.
5. WARNING: B
EFORE PROCEEDING, IT IS ESSENTIAL THAT
THE WARNING NOTES GIVEN IN SECTION 100-00 (UNDER THE
HEADING 'SAFETY PRECAUTIONS') ARE READ AND
UNDERSTOOD.
Disconnect the three valve hoses.
1. Pull off the vacuum pipe.
2. Release the clip and di sconnect the upper vapour
hose.
3. Release the clip and disconnect the lower vapour hose. Plug the hose (note the warning above).
1. R
emove the two mounting rubbers from the old valve and fit to
the new valve.
2. Fitting a new purge valve asse mbly is the reverse of the
removal procedure.