Operation CHARM: Car repair manuals for everyone.

Refit

Oil Tube Seal:





Refit
- Fit a new seal (2) to the oil filler tube lower housing (3).
- Fit a new manifold gasket onto the studs.
- Place the manifold assembly adjacent to its mounting studs and position the hoses and cables through the spaces in the manifold.
- Locate the manifold onto the mounting studs, ensuring that no cables are trapped between the faces.
- Fit the harness support brackets and the oil filler tube bracket to the manifold studs.
- Fit the earth leads to the manifold front stud.

Induction Manifold Fasteners:





- Fit the nuts, bolts and washers to secure the manifold, tightening in stages to ensure that the gasket is clamped evenly between the manifold faces (1).
- Fit the securing bolt to the dipstick tube.
- Fit the oil filler tube and retaining bolt.
- Connect the breather hose to the cam cover.
- Refit the hoses between the induction elbow, oil filler tube and the orifice control housing.
- Connect the electrical connections to the injectors and air sensor block.
- Connect the air conditioning hose to the inlet manifold.
- Remove the blanking plugs from the control housing hoses and connect the hoses.
- Tighten the clips.
- Fit the throttle cable bracket to the manifold and tighten the securing bolts.
- Connect the throttle cable and the return spring.
- Remove the blanking plugs from the fuel rail and the feed hose.
- Connect the feed hose to the fuel rail.
- Fit the three retaining clips to the feed hose (2).
- Remove the blanking plugs from the pressure regulator and feed hose.
- Connect the hose to the pressure regulator.
- Connect the throttle potentiometer block connector.
- Connect the idle adjustment stepper motor connector.
- Connect the hoses to the auxiliary air valve.
- Secure the harnesses to the support mounting brackets using the Ty-wraps.

Induction Elbow:





- Connect the air intake hose to the throttle body (3), align and tighten the hose clip (2).
- Fit the bolt (1) which secures the induction elbow to the left side inner wing.
- Check that the relay(s) which were removed when depressurizing the fuel system are correctly refitted and connect the battery.
- Start and run the engine to check for leaks.
- Stop the engine.
- Remove the wing protection sheet and close the bonnet.