Intake Air Plenum: Service and Repair

PLENUM CHAMBER

Remove
1. Disconnect battery negative lead.
2. Slacken clip securing intake hose to plenum chamber and release hose.
3. Remove split pin from throttle cable clevis pin.
4. Remove clevis pin.
5. Release and remove kick down cable clevis pin.
6. Disconnect vacuum hose from cruise actuator.
7. Release throttle cable from abutment bracket.
8. Remove front locknut from kick down cable.





9. Release cable from bracket.
10. Disconnect breather hose from plenum.
11. Release clip and disconnect multiplug from Throttle Position (TP) sensor.
12. Disconnect multiplug from Idle Air Control (IAC) motor.
13. Remove 6 bolts securing plenum chamber.
14. Release plenum chamber from ram pipe housing.
15. Fit approved hose clamp to water jacket coolant hoses.
16. Tighten clamp.
17. Position cloth to absorb coolant spillage.

Note: Do not carry out further dismantling if component is removed for access only.

18. Slacken clips securing coolant hoses to plenum.





19. Disconnect hoses and remove plenum chamber.
20. Place cloth over ram pipes to prevent ingress of foreign matter.





21. Remove 4 bolts securing water jacket to plenum chamber. Remove water jacket. Remove gasket and discard.
22. Remove 3 bolts securing throttle linkage bracket to plenum chamber. Remove bracket. Collect return spring.





23. Remove 2 Torx bolts securing TP sensor. Collect clamp plate. Remove TP sensor.
24. Remove 2 bolts securing IAC motor. Remove motor. Remove gasket and discard.

Refit
25. Ensure all mating surfaces are clean.
26. Fit TP sensor. Ensure drive engages correctly with throttle spindle.
27. Position clamp plate. Secure TP sensor with bolts. Tighten to 2 Nm.
28. Using a new gasket, fit IAC motor. Secure with bolts. Tighten to 2.3 Nm.
29. Ensure mating faces of water jacket and plenum chamber are clean.
30. Using a new gasket, fit water jacket. Secure with bolts. Tighten to 13 Nm.
31. Position throttle linkage bracket, fit and engage return spring.
32. Secure linkage bracket to plenum chamber with bolts. Tighten to 8 Nm.
33. Remove cloth from ram housing.
34. Ensure mating faces of plenum chamber and ram pipe housing are clean.
35. Position plenum chamber. Connect coolant hoses to water jacket. Secure with clips.
36. Remove clamp from coolant pipes. Remove cloth.
37. Apply a thin, uniform coating of Loctite 577 sealant to sealing face of plenum chamber.
38. Fit plenum chamber.
39. Fit plenum chamber bolts. Tighten to 24 Nm.
40. Connect multiplugs to TP sensor and IAC motor.
41. Connect breather hose to plenum chamber.
42. Fit kick down cable to abutment bracket and fit locknut.
43. Connect throttle cable to abutment bracket.
44. Connect vacuum hose to actuator.
45. Align throttle cable to lever. Fit clevis pin. Secure clevis pin with split pin.
46. Align kick down cable to lever.
47. Fit clevis pin and secure clip.
48. Connect intake hose and secure with clip.
49. Reconnect battery negative lead.
50. Top up cooling system.