Planning the next
AO Silver Member
Join Date: May 2007
Location: United Kingdom
This is how I do it ( there are subtle variations ) and is relative to phase 1. There will be differences for phase 2 :
Disconnect MAF and air temperature sensors from inlet pipe.
Disconnect breather pipe(s) from throttle body/inlet pipe.
Remove inlet piping from air filter to throttle body ( including resonator box )
Disconnect the small pipe from the header tank to the throttle body and plug it so it doesn't leak.
Undo the header tank and swivel it out of the way towards the radiator
Disconnect throttle cable.
Disconnect the small pipe on the throttle body from the intake manifold
Disconnect idle actuator & throttle position sensors from throttle body.
Disconnect three connectors at belt end of plenum chamber
Disconnect vacuum pipe at connector near engine steady
Disconnect fuel vapour recovery pipe from plenum ( blue pipe )
Remove cover from bulkhead mounted relay/fuse box.
Undo the loom & heater pipe clips under the throttle body
Undo the three Torx 30 bolts holding the heater pipe/loom bracket to the base of the throttle body & remove bracket
Undo the bolt holding the plenum to the cylinder head near the throttle body ( 13mm ) noting it's position and angle
With a stubby ratchet undo the same bolt at the belt end by reaching right under the plenum ( this is why the header tank gets moved out of the way so you can get your arm right in )
Undo the plenum mounting bolt on the throttle body side of the steady bar ( 15mm )
With a stubby 15mm spanner, undo the bolt on the other side of the steady bar. This is the difficult one!
Undo the 4 Clic clips for the rubber interconnects between the plenum and intake manifold.
Remove the plenum with throttle body ( rotate and lift )
Remove belt end road wheel
Remove inner wing access hatch
Slacken auxiliary drive belt tensioner and ease it off the crank pulley
Disconnect the wires from the alternator
Remove the 3 alternator mounting bolts.
On phase 2 you'll also have to disconnect the variable length inlet manifold connecter.
The difficult bit is the 4 plenum mounting bolts. The manual says to remove them from below but you need a very long socket extension and even then, there's a metal tab which makes the belt side bolt of the steady bar difficult to access. But from the top, they may be too tight to slacken with a stubby ratchet and spanner.