Plastic manifold stub pipes - renew

Refit

1. Clean mating faces of inlet manifold and manifold chamber.
2. Fit new ’O’ ring to throttle housing.
3. Fit new gasket to inlet manifold and position manifold chamber.
4. Progressively tighten bolts securing manifold chamber to inlet manifold to 25 Nm.
5. Align throttle housing to manifold chamber and bracket to housing.
6. Fit bolts securing throttle housing to manifold chamber and tighten to 7 Nm.
7. Connect multiplug to MAP sensor.
8. Connect multiplug to IACV.
9. Connect breather hose to manifold. chamber and secure with clip.
10. Connect hose to IACV.
11. Connect throttle cable to throttle cam.
12. Secure throttle cable adjusting nut to abutment bracket.
13. Secure throttle cable to clip on manifold.
14. Connect purge hose to manifold and secure with clip.
15. Connect brake servo vacuum hose to manifold chamber
16. Connect battery earth lead.
17. Adjust throttle cable. See ENGINE MANAGEMENT SYSTEM - MEMS, Adjustments.

PLASTIC MANIFOLD STUB PIPES - RENEW

Service repair no - 30.15.42

In the event of one of the plastic manifold stub pipes breaking during a repair operation they can be replaced using the following procedure. Read and study the procedure before commencing a repair.

Renew

1. Remove plastic inlet manifold. See this section.
2. Position manifold on a work surface and clamp on manifold flange.

NOTE: Support manifold chamber.

3. If the damaged pipe has broken above the boss face, file the pipe level with the boss face.
4. Using a vernier caliper, micrometer or similar, measure the diameter of the stub pipe which has broken.

5 mm stub pipe (Part No. UKC 2487)

5. Select a 5 mm drill.

NOTE: The drill must be clean and free of grease and oil.