Intake Air Plenum: Service and Repair

Service repair no - 19.22.46

Remove
1. Disconnect battery negative lead.
2. Slacken clip securing intake hose to plenum chamber. Release hose.
3. Remove throttle and cruise control cables from throttle linkage.
4. Remove throttle and cruise control cable from abutment bracket.
5. Release harness clip from throttle linkage bracket.
6. Disconnect breather hose from plenum chamber.












7. Disconnect multiplugs from idle air control (IAC) and throttle position sensor (TP Sensor).
8. Remove 6 bolts securing plenum chamber. Remove plenum chamber from ram pipe housing.
9. Place cloth over ram pipes to prevent ingress of foreign matter.

Do not carry out further dismantling if component is removed for access only.
10. Clamp coolant hoses with an approved hose clamp.
11. Disconnect coolant hoses from water jacket. Remove plenum chamber.
12. Remove 4 bolts securing water jacket to plenum chamber. Remove water jacket. Remove gasket and discard.
13. Remove 3 bolts securing throttle linkage bracket to plenum chamber. Remove bracket. Collect return spring.







14. Remove 2 bolts securing TP sensor. Collect clamp plate. Remove TP sensor.







15. Remove 2 bolts securing IAC. Remove motor. Remove gasket and discard.

Refit
16. Ensure all mating surfaces are clean.
17. Fit TP sensor. Ensure drive engages correctly with throttle spindle.
18. Position clamp plate. Secure TP sensor with bolts. Tighten to 2 Nm. (2 lbf. ft)
19. Using a new gasket, fit IAC. Secure with bolts. Tighten to 2.3 Nm. (1.8 lbf. ft)
20. Ensure mating faces of water jacket and plenum chamber are clean.
21. Using a new gasket, tit water jacket. Secure with bolts. Tighten to 13 Nm. (10 lbf.ft)
22. Position throttle linkage bracket, fit and engage return spring.
23. Secure linkage bracket to plenum chamber with bolts. Tighten to 8 Nm. (6 lbf. ft)
24. Ensure mating faces of plenum chamber and ram pipe housing are clean.
25. Position plenum chamber. Connect coolant hoses to water jacket. Secure with clips.
26. Remove clamp from coolant pipes.
27. Apply a thin, uniform coating of Loctite 577 sealant to sealing face of plenum chamber.
28. Fit plenum chamber.
29. Fit plenum chamber bolts. Tighten to 24 Nm. (18 lbf. ft)
30. Connect multiplugs to TP sensor and IAC.
31. Connect breather hose to plenum chamber.
32. Secure harness clip to throttle linkage bracket.
33. Engage throttle cable and cruise control cable to abutment. Secure cruise control cable with 'C' clip.
34. Align cables to throttle linkage. Fit clevis pins. Secure clevis pins with split pins.
35. Adjust throttle cable. Adjustments
36. Connect intake hose. Secure with clip.
37. Reconnect battery negative lead.
38. Top up cooling system.
39. Check base idle speed. Adjust if necessary.

See ENGINE TUNING DATA, Information. Specifications