Plastic manifold stub pipes

PLASTIC MANIFOLD STUB PIPES

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.

6. Position a fibre washer on drill shaft, 13 mm from tip of drill (dimension A in illustration).

6 mm stub pipe (Part No. JZX 2000)

7. Select a 6 mm drill.

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

8. Position a fibre washer on drill shaft, 15 mm from tip of drill (dimension A in illustration).

Both stub pipes

9. Carefully drill hole to depth.

WARNING: Safety goggles must be worn when drilling.

10. Lightly chamfer edge of drilled hole.
11. Select replacement stub pipe, spray stub and drilled hole with Loctite activator N.
12. Allow activator to fully dry and DO NOT contaminate surfaces.
13. Lightly smear drilled hole and stub pipe with Loctite 648.
14. Fit stub pipe into plastic manifold.

NOTE: Leave manifold for one hour to allow loctite to partially cure.

15. Un-clamp manifold from work bench and using an air line, blow out any excess loctite from stub pipe and swarf from manifold.
16. Fit plastic inlet manifold. See this section.

NOTE: When connecting hose to repaired stub pipe, avoid twisting or excessive bending.

NOTE: The vehicle is fit for service, but full strength of joint will be achieved after approximately ten hours.