Page 550 of 2490

14
. WARNING: TH
E FOLLOWING OPERATIONS REQUIRE
THE USE OF COMPRESSED AIR - ALWAYS WEAR SUITABLE EYE
PROTECTION.
Remove, clean and measure the shims.
1. Surround the immediate wo rking area with clean rag
to contain any loose objects and shims displaced by
the compressed air.
2. Use 303 - 590 Air Gun (with a fan nozzle) aimed at the edge of the shim to lift it from the tappet.
Remove the shim from each tappet, noting the
position of each.
15 . Cl
ean and measure the thickness of each shim.
16. Assess the increase or decrease required in shim thickness to
produce the correct valve clearance.
17. Select two shims of the correct size, lubricate each and fit
each to the respective tappet (as calculated in the previous
step). Shims must be fitted with the size marking facing the
tappet NOT the cam.
18 . Loos
en the knurled screws on 303 - 540 attachment to allow
the valve springs to return to their normal position.
19. Check the valve clearance of the two valves. If the clearance
is correct, remove the attachment from the base plate. transfer
the attachment to the other two valves which are in position to
be adjusted.
20. Repeat the adjustment procedure, as described in the
Summary.
21. Refit the cam covers and associated components. Refer to
Operations 12.29.43 and 12.29.44.
22. Refit the engine covers.
23. Check the engine oil level; rectify as necessary.
24. Move the engine compartment cover from the service position
and connect the gas struts.
25. Remove the paint protection sheets and close the cover.
26. Connect the battery and fit the battery cover.
Refe
r to the Battery Reconnection Procedure 86.15.15.
Page 704 of 2490
Engine - Intake Manifol
d
In-v
ehic
le Repair
Remov
a
l
W
A
RNING: BEFORE PROCEEDING, IT IS ESSENTIAL THAT
THE WARNINGS GIVEN IN SECTION 100-00 (UNDER THE
HEADING 'SAFETY PRECAUTIONS') ARE READ AND UNDERSTOOD.
S p
ecial Tool(s)
Qu
ic
k Fit Connector Release Tool
310-044
Qu ic
k Fit Connector Release Tool
310-054
Inject or Remov
al Tools
303-539
F u
el Injection Pressu
re Test Equipment
310-058
1. Open the engine compartment and fit paintwork protection
sheets.
2. Carefully remove the en gine covers, taking care not to damage
the plastic fixings or the rubber inserts.
3. Depress
urise the fuel system.
E
n
sure that the ignition is
switched off and remove the
valve cap from the fuel cross-over pipe. Place a cloth
under the valve to collect any spillage.
Pla c
e a closed container, su
itable for collecting fuel,
adjacent to the vehicle. Remove the lid.
4. Connect the fuel injection pres sure test equipment 310 - 058
Page 718 of 2490

Engine - Intake Manifold Gaskets
In-vehicle Repair
Removal
WARNING: BEFORE PROCEEDING, IT IS ESSENTIAL THAT THE WARNINGS GIVEN IN SECTION 100-00 (UNDER THE
HEADING 'SAFETY PRECAUTIONS') ARE READ AND UNDERSTOOD.
Special Tool(s)
Quick Fit Connector Release Tool
310-044
Quick Fit Connector Release Tool
310-054
Fuel Injection Pressu re Test Equipment
310-058
1. Open the engine compartment and fit paintwork protection
sheets.
2. Carefully remove the en gine covers, taking care not to damage
the plastic fixings or the rubber inserts.
3. Depressurise the fuel system.
Ensure that the ignition is switched off and remove the
valve cap from the fuel cross-over pipe. Place a cloth
under the valve to collect any spillage.
Place a closed container, su itable for collecting fuel,
adjacent to the vehicle. Remove the lid.
4. Connect the fuel injection pres sure test equipment 310 - 058
(or other suitable type). Insert the drain / bleed tube into the
fuel container. Follow the ma nufacturer's instructions and
depressurise the fuel system.
Page 729 of 2490

Engine - Intake Manifold LH
In-vehicle Repair
Removal
WARNING: BEFORE PROCEEDING, IT IS ESSENTIAL THAT THE WARNINGS GIVEN IN SECTION 100-00 (UNDER THE
HEADING 'SAFETY PRECAUTIONS') ARE READ AND UNDERSTOOD. 1.
Open the engine compartment and fit paintwork protection
sheets.
2. Disconnect the batt ery ground cable.
Remove the battery cover.
3. Depressurise the fuel system.
Ensure that the ignition is switched off and remove the
valve cap from the fuel cross-over pipe. Place a cloth
under the valve to collect any spillage.
Place a closed container, su itable for collecting fuel,
adjacent to the vehicle. Remove the lid.
4. Connect the fuel injection pres sure test equipment 310 - 058
(or other suitable type). Insert the drain / bleed tube into the
fuel container. Follow the ma nufacturer'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. Drain the radiator coolant. Refer to Operation 26.10.01.
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
Page 734 of 2490

Engine - Intake Manifold RH
In-vehicle Repair
Removal
WARNING: BEFORE PROCEEDING, IT IS ESSENTIAL THAT THE WARNINGS GIVEN IN SECTION 100-00 (UNDER THE
HEADING 'SAFETY PRECAUTIONS') ARE READ AND UNDERSTOOD. 1.
Open the engine compartment and fit paintwork protection
sheets.
2. Disconnect the batt ery ground cable.
Remove the battery cover.
3. Depressurise the fuel system.
Ensure that the ignition is switched off and remove the
valve cap from the fuel cross-over pipe. Place a cloth
under the valve to collect any spillage.
Place a closed container, su itable for collecting fuel,
adjacent to the vehicle. Remove the lid.
4. Connect the fuel injection pres sure test equipment 310 - 058
(or other suitable type). Insert the drain / bleed tube into the
fuel container. Follow the ma nufacturer'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. Drain the radiator coolant. Refer to Operation 26.10.01.
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
Page 739 of 2490

Engine - Intake Manifold Gasket LH
In-vehicle Repair
Removal
WARNING: BEFORE PROCEEDING, IT IS ESSENTIAL THAT THE WARNINGS GIVEN IN SECTION 100-00 (UNDER THE
HEADING 'SAFETY PRECAUTIONS') ARE READ AND UNDERSTOOD. 1.
Open the engine compartment and fit paintwork protection
sheets.
2. Disconnect the batt ery ground cable.
Remove the battery cover.
3. Depressurise the fuel system.
Ensure that the ignition is switched off and remove the
valve cap from the fuel cross-over pipe. Place a cloth
under the valve to collect any spillage.
Place a closed container, su itable for collecting fuel,
adjacent to the vehicle. Remove the lid.
4. Connect the fuel injection pres sure test equipment 310 - 058
(or other suitable type). Insert the drain / bleed tube into the
fuel container. Follow the ma nufacturer'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. Drain the radiator coolant. Refer to Operation 26.10.01.
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
Page 744 of 2490

Engine - Intake Manifold Gasket RH
In-vehicle Repair
1. Open the engine compartment and fit paintwork protection
sheets.
2. Disconnect the batt ery ground cable.
Remove the battery cover.
3. WARNING: BEFORE PROCEEDING, IT IS ESSENTIAL THAT THE WARNINGS GIVEN IN SECTION 100-00 (UNDER THE
HEADING 'SAFETY PRECAUTIONS') ARE READ AND
UNDERSTOOD.
Depressurise the fuel system.
Ensure that the ignition is switched off and remove the
valve cap from the fuel cross-over pipe. Place a cloth
under the valve to collect any spillage.
Place a closed container, su itable for collecting fuel,
adjacent to the vehicle. Remove the lid.
4. Connect the fuel injection pres sure test equipment 310 - 058
(or other suitable type). Insert the drain / bleed tube into the
fuel container. Follow the ma nufacturer'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. Drain the radiator coolant. Refer to Operation 26.10.01.
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.
Page 897 of 2490
• WARNINGS:
4. Remove the engine compartment cover (bonnet).
1. Apply masking tape to th e front edge of the engine
compartment cover to protect the paintwork during
removal and storage.
2. With assistance, support the cover and release the
gas struts.
5. With assistance, release the six bolts which retain the cover
(bonnet) and lift the cover clear.
Disconnect the ground cable from the left hand hinge.
6. Remove the engine covers
7. Drain the cooling system. Refer to Operation 26.10.01.
Conserve as much of the coolant as possible to refill the
system.
8. Depressurise the air conditioni ng system. Refer to Operation
82.30.30 and note all Wa rnings and Cautions.