Plenum chamber

PLENUM CHAMBER

Service repair no - 19.42.02

Remove

1. Remove engine acoustic cover. See BODY, Exterior fittings.

2. Remove 2 bolts securing EGR pipe to plenum chamber and disconnect pipe.
3. Remove bolt securing plenum chamber to camshaft cover bracket.
4. Remove 2 bolts securing plenum chamber to inlet manifold.
5. Loosen clip and disconnect intercooler outlet hose from plenum chamber.
6. Release plenum chamber and discard gasket.

Refit

1. Clean mating faces of inlet manifold and plenum chamber.
2. Using a new gasket, position plenum chamber to inlet manifold, fit bolts and tighten to 9 Nm.
3. Position EGR pipe to plenum chamber, fit bolts and tighten to 9 Nm.
4. Fit bolt securing plenum chamber to camshaft cover bracket and tighten to 9 Nm.
5. Connect intercooler outlet hose to plenum chamber and secure clip.
6. Fit engine acoustic cover. See BODY, Exterior fittings.

INTERCOOLER

Service repair no - 19.42.15

Remove

1. Remove radiator LH cooling fan. See COOLING SYSTEM - ’L’ SERIES, Repairs.
2. Raise front of vehicle.

WARNING: Support on safety stands.

3. Remove front centre underbelly panel. See BODY, Exterior fittings.

4. Loosen clip and disconnect lower hose from intercooler.
5. Remove lower Torx bolt securing intercooler to radiator.
6. Remove upper Torx bolt securing intercooler to radiator.
7. Remove 2 bolts securing intercooler mounting bracket to bonnet locking platform.
8. Remove bracket.
9. Carefully manoeuvre intercooler from vehicle. Do not carry out further dismantling if component is removed for access only.
10. Remove mounting rubber from intercooler and fit to new intercooler.