Intake Air Plenum: Service and Repair

Common Chamber Removal:

REMOVE

1. Disconnect ground cable terminals from common chamber.

Ground Connection:

2. Disconnect two cable harness connectors from throttle valve assemble and MAT sensor harness connector and accelerator cable from throttle valve assembly and common chamber.
3. Remove:
a. PCV hose.
b. Intake air duct.
c. MAP sensor hose.
d. Vacuum booster hose.
e. Canister hoses.
f. Canister pipes and MAP sensor pipe with bracket.
g. Fuel pressure regulator vacuum hose.

4. Remove throttle valve assembly and heating hoses from common chamber.
5. Loosen EGR pipe and valve fixings and clip.

Harness Clip:

6. Disconnect induction control vacuum hose, generator cable harness clip, common chamber bracket and engine hanger from common chamber.
7. Remove common chamber.

REFIT

Common Chamber Removal:

Reverse steps to refit noting the following:

Be sure all sealing surfaces are completely clean.
Use a new gaskets.
Tighten common chamber fasteners to 17 ft lb (23 Nm)

Tighten EGR pipe to EGR valve to 32 ft lb (44 Nm)

Tighten EGR pipe to exhaust pipe to 21 ft lb (28 Nm)

Check intake and EGR pipe for leaks.