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Discussion Starter · #1 ·
I'm working on checking valve clearances and changing the timing belts. To do this I need to remove the middle timing cover. To do that I need to remove the blow-by tank. To do that I need to remove the airbox. I followed all the steps in the service manual and it will still not come out. I I have it off both cylinders and it comes out about 1 or 2 inches but is firmly held in place underneath somewhere. The manual said to remove the secondary air valve by pulling it off the pins but failed to mention removing the screw and bracket for that valve or it would definitely be in the way. I did that. Would love any tips or information about removing the airbox. Has anyone removed the middle timing cover without removing the airbox?

Please help!
 

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Discussion Starter · #2 ·
Figured it out. Besides all the steps listed in the service manual, first remove the radiator. This allows access to connections to the bottom side of the airbox not mentioned in the manual. Also removal of the radiator will facilitate re-installing the airbox.
 

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Hi Rhino TX

I hope you still monitor this forum from time to time...

Do you happen to have any pics of the connections on the bottom side of the airbox? I was at the part where the workshop manual states to „remove the airbox“ but it wouldn‘t move, not even a little, so I stopped before breaking anything...

I‘m trying to gain access to the throttle bodies to remove and clean them. I would prefer to keep the radiator on if possible. With your knowledge after having performed this procedure, would you remove the radiator again or would you do it differently?

I am also having some second thoughts on how difficult it will be to get the airbox back on... Did you have any major difficulties?

Thanks for any advice!
 

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Hi Rhino TX

I hope you still monitor this forum from time to time...

Do you happen to have any pics of the connections on the bottom side of the airbox? I was at the part where the workshop manual states to „remove the airbox“ but it wouldn‘t move, not even a little, so I stopped before breaking anything...

I‘m trying to gain access to the throttle bodies to remove and clean them. I would prefer to keep the radiator on if possible. With your knowledge after having performed this procedure, would you remove the radiator again or would you do it differently?

I am also having some second thoughts on how difficult it will be to get the airbox back on... Did you have any major difficulties?

Thanks for any advice!
See my post on the topic. DVT Belt and Desmo valve service, some pointers I did this job last spring. Next time I'll avoid removing the airbox. Most of the work with this job is messing with the airbox. There is a way to do the job without removing the middle timing belt cover. It would be fiddly, sure, but anything to avoid airbox mess. As for removal of the radiator is not a big deal, can't tell you if the job is doable by leaving the radiator intact. You cannot remove the airbox without removing the radiator. Post your results!!
 

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Thanks, Essing for the info!
I want to get to the throttle bodies, so airbox removal is necessary. I will give it another try as soon as I get a little bit if time and post back with the results. I guess, I will be replacing the coolant in the process...
 

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@Essing I finally got around to removing the airbox today. At the end, I just loosened the radiator in order to get to the bottom of the airbox. I had some difficulties with the fuel hose on the left side of the airbox. There is very little space between airbox and frame and the hose is quite hard.
I DO NOT look forward to reinstalling it... but I guess, one day I will have to! Anyhow, thank you for your help!
 

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I have just done the same job. removed the entire airbox in order to replace the fuel line from fuel pump to injectors (split)
After the tank is off and the ECU out of the way, you can remove the airbox.
DO NOT split the 2 halves of the airbox along the middle with it in situ.
Firstly the screws that hold the 2 halves together are very awkward to get to, but once they are all removed you cannot remove the top piece as the air intake trumpets on inside the air box catch on the top as you try to remove it. (ask me how I know)
You have to remove the whole airbox complete.
Remove the 2 top rad bolts to drop the rad slightly out of the way, undo all the electrical connectors. pull the drain/vent line out (which connects to the front bottom of the airbox) undo the 2 screws that hold the box (to sure what it is) onto the right side of the airbox between the frame bars, and pull the box away from the airbox. now undo the large jubilee clips that secure the air intakes to the bottom of the airbox.
It should now pull out, wiggle it up off the 2 inlet manifolds, then wiggle it down at the front, and up at the back and pull backwards, it comes out honest!!!
It is tight and tends to catch on the front frame at the top.
When refitting push it back in (tight). To get the manifolds on, line it up as best you can, get the front one on firs, its hard because you can't push down very well. I used a large spanner to pry bar GENTLY between the horizontal frame tube and the top of the airbox. This pushed the airbox down at the front and seated it onto the manifold, the rear is much easier as you can wiggle and push down more easily. Do up the jubilee clips, reconnect everything and job done.
PIG of a job, I am sure I could do it quickly a second time, but I hope I will never have to !!!
Good luck.
 
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