Has anyone tried removing the intake manifold *without* removing the throttle elbow?
 

Folks,

Deep in my first disassembly of my 2001 XK8 to change the valley heater hoses, thermostat housing, thermostat, water pump ...

I've searched far and deep and long, and have found many helpful threads and procedures ... but I in a bit of a quandary, and it's this: I am desperately trying to get this job done today/tonight - and it's already tonight. I can't get any more parts this evening (everything is closed) and I got to the step where you remove the throttle body elbow and ... after researching on here, I realized that I need a new compression fitting on the brake booster pipe that goes into the throttle body elbow - which means that I can't remove it tonight.

I have unbolted the (6) bolts that hold the elbow to the rear of the intake manifold, and can't find any other bolts. I've unbolted the intake itself using the reverse of the factory tightening pattern.

The front is a tiny bit loose - but the back is going nowhere, and given that this is a plastic (presumably) EXPENSIVE intake manifold - I don't want to force anything and crack it.

It might just be that a gentle couple of taps with a rubber mallet will set it free from the rear plate - but ...

If any of the experts on here have any insight tonight, it would be appreciated.

Thanks!

The elbow stays with the plastic manifold!!!!!
The brake booster plastic line slides out of the couple on the throttle housing elbow.(unless you forced it and broke it!!!)

The throttle elbow is held in place on each side with M8x1.25mm bolts (10mm head) to a bracket mounted to the cylinder block. Remove the 10 M8x1.25mm plastic intake manifold bolts and the 2 elbow bolts (along with the metal pipe bracket for the the heater coolant) and the assy should lift OFF.

There are fuel lines and harnesses to be moved but it is all there in plain view (except for the elbow bolts apparently).

bob

Thanks to another member, I understood how to remove the line into the elbow - came right out no problem :D

As to the elbow - ok - I"ll bolt that back to the manifold, and unbolt the elbow from the bracket on the engine like most of the procedures show. Damn but those vacuum lines are on there as if they were cemented!

One thing I do when the manifold/elbow is off.........
I bend the throttle elbow mount brackets on the block APART slightly to allow the elbow to drop into place when installing the assy back onto the engine.

Start ALL the bolts loose and then tighten after all are threaded into their holes.

bob

Success! Well ... mostly :D

I have bolted the elbow carefully and just snug back to the intake manifold ... removed the two bolts holding said elbow to the bracket - and now the manifold moves freely (I've only gently tested it).

However ... the BIG vacuum line going from drivers side (LHD) into the elbow fitting - it has a plastic ring around the connector that holds the "T" vacuum line to the elbow pipe ... what I read previously was "just push on the tang on the bottom of that plastic connector and it will pop off".

Not for me - no amount squeezing top to bottom, or side to side on that plastic ring will release that monster T connection. This is the only bit stopping me from proceeding tonight (yes, this has turned into a multiday after work special) ...


https://cimg6.ibsrv.net/gimg/www.jag...0ebe67e334.jpg

the fat pipe on the left is the one I'm referring to - whether or not this is the exact same elbow (it's not)

Might be slightly different as yours is a 2001 - do you mean this one:

https://cimg0.ibsrv.net/gimg/www.jag...487ee97b06.jpg

I can see that there's a link but it ends up with an error.

Here's a picture of my actual part:



https://cimg7.ibsrv.net/gimg/www.jag...921b4c7252.jpg

That is the PART LOAD BREATHER pipe and the connector uses a special tool 303-623 to spread the clips on the sides. (See TSB 303-17)

You can use a pointed hook tool to gently pry the clips away from the barbed port to free the convoluted hose.

bob

Hi Jimbo,
Maybe it's the shadow (or more likely my eyesight) but I can't make out the push-fit connector in your pic, although I see the 'corrugated' pipe it's attached to.

Here's a snip of the lhs of the TB elbow from underneath. The connector fits over the larger pipe - but it looks different to yours:

https://cimg4.ibsrv.net/gimg/www.jag...1f7a63e363.jpg


Anyway, that connector is released by squeezing the circular ring hard in such a way as it pushes out the two latches:

https://cimg7.ibsrv.net/gimg/www.jag...2fd9faa016.jpg

It's a pretty tight fit so you may need to pull hard. Beware that the whole pipe will have gone brittle from the heat over the years and may well fall apart in your hands (mine did).

HTH,
Mike

Thanks, Bob. I originally thought that was part of the connector as mine has a slightly modified version of the tool at both ends (with barbs on the legs to keep it in place). Have only seen one picture of the tool in situ & it doesn't seem to come with the replacement breather assembly, so assumed Jaguar had seen another sales opportunity :)

https://cimg9.ibsrv.net/gimg/www.jag...c1114a2953.gif

Mike and Bob,

Thank you both so much for the help. I honestly get so frustrated and/or anxious about getting repairs done in a given amount of time that I am sorely tempted to just rip and tear at whatever is resisting me - but decades of experience have shown me how much more trouble that creates - so I walk away, research some more, and as here, ultimately post a question - and almost always get the help I need faster than I can reasonably expect :-)

​​​​​​​You guys rock.

Just took my throttle body off yesterday. it was a bitch but there wasn't that locking piece in there when I started.

Sorry wrong post...

Hi Greg, I usually glance through a thread. This one, I took the time to read. Really thoughtful and impressive. This ought to become a sticky on how to R&R a turbo 400.

What was the failure mode of what you took out?

I have a 1992 Coupe and a 1992 Conv. I keep my fingers crossed I don't have to replace a 400 on either one. Too old now to do such a job.

By the way, I worked at PSA on the tele-diag and diag2000 programs for the Peugeot Citroen service bays. Lived in Neuilly Sur-Seine and commuted to Cergy Pontoise..