Plastic manifold stub pipes – renew

PLASTIC MANIFOLD STUB PIPES – RENEW

Service Repair No. 30.15.42

Part No's.

Small stub pipe – UKC 2487

Large stub pipe – JZX 2000

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.

1. Remove plastic inlet manifold, see Plastic inlet manifold gasket.
2. Position manifold onto a work surface, clamp manifold flange.

Note: Support manifold chamber.

3. If the fractured pipe has broken above boss face, file fracture back to boss face.
4. Note whether smaller or larger plastic stub pipe is broken using a vernier caliper, micrometer or similar.

Small stub pipe

5. Select a 5 mm drill.

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

6. Position a fibre washer to drill, set 13 mm from tip of drill (Dimension A shown).
7. Carefully drill hole to depth.

WARNING: Safety goggles must be worn during above.

Large stub pipe

8. Repeat steps 5 to 7 instead using a 6 mm drill and drilling to a depth of 15 mm.
9. Lightly chamfer edge of drilled hole.
10. Select replacement stub pipe spray stub pipe and drilled hole with Loctite Activator N.

Note: Allow activator to fully dry and DO NOT contaminate surfaces.

11. Lightly smear drilled hole with Loctite 648 using a matchstick and apply Loctite 648 to stub pipe.
12. Fit stub pipe into plastic manifold.

Note: Leave manifold for one hour to allow Loctite to partially cure.

13. Un – clamp manifold from work bench and using an air line blow out any excess Loctite from stub pipe and swarf from manifold.
14. Refit plastic inlet manifold, see Plastic inlet manifold gasket.

Note: When fitting rubber pipe to repaired stub pipe, avoid twisting or excessive bending.

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