Intake Air Plenum: Service and Repair

Service repair no - 19.22.46

Remove







1. Remove battery cover and disconnect battery.
2. Loosen clip securing air intake hose to plenum chamber.
3. Disconnect air intake hose from plenum chamber.
4. Remove split pin and clevis pin securing throttle cable to throttle linkage.
5. Remove split pin and clevis pin securing cruise control cable to throttle linkage and release cable adjuster from abutment bracket.
6. Remove 'C' clip securing cruise control cable abutment to bracket and position cable aside.
7. Release clip securing throttle cable abutment to bracket and position cable aside.
8. Release clip securing harness to cable abutment bracket and position aside.
9. Disconnect breather hose from plenum chamber.
10. Release clip and disconnect purge hose from plenum chamber.
11. Disconnect multiplug from throttle potentiometer.
12. Disconnect multiplug from stepper motor.
13. Remove 6 bolts securing plenum chamber to ram housing.
14. Release plenum chamber from ram housing.
15. Fit hose clamp to 2 plenum chamber coolant hoses.
16. Position cloth to catch spillage.







17. Release clip securing coolant hose to plenum water jacket and disconnect hose.
18. Loosen clip securing coolant hose to plenum water jacket and disconnect hose.
19. Remove plenum chamber assembly.
20. Place clean cloth over intake pipes to prevent dirt ingress.

Do not carry out further dismantling if component is removed for access only.
21. Remove 4 bolts securing water jacket to plenum chamber.
22. Remove water jacket and sealing gasket.
23. Position throttle linkage to gain access to bolt.








24. Remove 3 bolts securing throttle linkage to plenum chamber.
25. Remove throttle linkage and bracket.
26. Collect spring.








27. Remove 2 bolts securing throttle potentiometer to plenum chamber.
28. Collect clamp plate.
29. Remove throttle potentiometer.
30. Remove 2 bolts securing stepper motor to plenum chamber.
31. Remove stepper motor and collect gasket.
32. Position throttle linkage bracket and spring to plenum chamber.
33. Engage spring to linkage.
34. Fit bolts securing throttle linkage to plenum and tighten to 8 Nm. (6 lbf. ft)
35. Clean mating faces of throttle potentiometer and stepper motor.
36. Fit throttle potentiometer, ensuring spindle is correctly engaged.
37. Fit retaining plate and bolts and tighten to 2 Nm (1.5 lbf. ft).
38. Fit NEW stepper motor gasket to plenum chamber.
39. Fit stepper motor.
40. Fit bolts securing stepper motor to plenum chamber and tighten to 2 Nm. (1.5 lbf. ft)
41. Clean mating faces of water jacket and plenum chamber.
42. Fit NEW water jacket gasket to plenum chamber.
43. Fit water jacket to plenum chamber.
44. Fit bolts securing water jacket to plenum chamber and tighten to 13 Nm. (10 lbf. ft)


Refit
45. Clean mating faces of plenum chamber and ram housing.
46. Connect coolant hose to water jacket and secure with clip.
47. Connect second coolant hose to water jacket and secure with clip.
48. Remove hose clamps.
49. Apply a thin, uniform coating of Loctite 577 sealant to mating face of plenum chamber.
50. Fit plenum chamber to ram housing.
51. Fit bolts securing plenum chamber to ram housing and tighten to 24 Nm. (18 lbf. ft)
52. Connect multiplugs to stepper motor and throttle potentiometer.
53. Connect purge hose to plenum chamber. Ensure connector is securely mated.
54. Connect breather hose to plenum chamber.
55. Position harness to throttle linkage bracket and secure clip.
56. Engage throttle cable abutment clip to bracket.
57. Align throttle cable to throttle linkage, fit clevis pin and split pin.
58. Position cruise control cable abutment to bracket and secure with 'C' clip.
59. Align cruise control cable to throttle linkage, fit clevis pin and split pin.
60. Adjust throttle cable. Adjustments
61. Connect air intake hose to plenum chamber and secure with clip.
62. Connect battery and fit cover.
63. Top up cooling system.
64. Check base idle speed. Adjust if necessary.

See ENGINE TUNING DATA, Information. Specifications