Ducati Diavel
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Ducati Diavel Service Manual: Removal the airbox and throttle body

Ducati Diavel Service Manual / Fuel/exhaust system / Airbox - throttle body / Removal the airbox and throttle body

Removal the airbox and throttle body


Loosen the screws (a) and remove the plate (b) that fixes the main wiring to the airbox.

Removal the airbox and throttle body


Undo the screws (17) and remove the air pressure sensors (9) with the support (19).

Removal the airbox and throttle body


Release the hoses (c) of the air pressure sensors (9) from the tab (d) on the airbox.

Removal the airbox and throttle body


Operating on the right side of the vehicle, disconnect connector (e) from the aps sensor.

Removal the airbox and throttle body


Operate on the vehicle lh side, disconnect connector (f) of the tps/etv motor.

Removal the airbox and throttle body


Loosen the clamp (6) that retains the blow-by pipe to the airbox

Removal the airbox and throttle body


Loosen the clamp (21) that retains the drain hose to the airbox.

Removal the airbox and throttle body


Loosen the clamps (6) that retain the airbox to the intake manifolds, and slide it out of its housing.

Removal the airbox and throttle body


Removal the airbox and throttle body


Operating on both throttle grip cables (h) and (m), loosen the nuts (l) and, turning the throttle body pulley (g), slide the two throttle grip cables (h) and (m).

Removal the airbox and throttle body


Removal of the fuel injectors

Operating on both intake manifolds, disconnect the connectors (n) that connect the main wiring to the injectors, loosen the fuel pipe retaining screws (p) and slide out the two injectors (3).

Removal of the fuel injectors


Refitting the injectors

Operate on both intake manifolds, check the presence of the o-rings (2) and (q) on injectors (3). Apply prescribed grease on o-rings (2) and (q) of injectors (3).

Insert the injectors in the relevant seats on the intake manifolds.

Important

To avoid damaging the o-rings, insert the injectors fully home on the intake manifolds by keeping them in line with the relevant seat.

Refitting the injectors


Operate on both intake manifolds, position the fuel pipes fittings on the injectors.

Important

To avoid damaging the injectors o-rings insert the fittings by holding them in line with the injectors.

Keep the fittings pressed on the injectors, then start and tighten the screws (p) fully home.

Tighten the retaining screw (p) to a torque of 5 nm +/- 10% (sect. 3 - 3, Frame torque settings).

Connect the main wiring connectors (n) to the injectors.

Refitting the injectors


Disassembly of the airbox - throttle body

Undo the six screws (16).

Disassembly of the airbox - throttle body


Remove the throttle body (4) from the filter box (1) with the intake manifolds (14).

Disassembly of the airbox - throttle body


Disassembly of the airbox - throttle body


Reassembly of the airbox - throttle body

If removed, fit the seals (13) in the seats on the filter housing (1).

Note

To better insert the seals (13) use lubricant specific for rubber.

Reassembly of the airbox - throttle body


If removed, insert the gaskets (15) in the seats (k) of the intake ducts (26).

Reassembly of the airbox - throttle body


If removed, refit the intake ducts (14) on throttle body (4) and apply prescribed threadlocker to the screws (5) and tighten them to a torque of 3.5 Nm +/- 10% (sect. 3 - 3, Frame torque settings) following the sequence indicated in figure.

Important

After tightening, visually check that the seals (15), previously fitted on the intake funnels, are still in their seats, and that the intake funnels are perfectly coupled with the throttle body.

Reassembly of the airbox - throttle body


Reassembly of the airbox - throttle body


Fasten the throttle body (4) to the airbox (1).

Position and tighten the fixing screws (16) and tighten them to the torque of 5 nm +/- 10% (sect. 3 - 3, Frame torque settings), following the sequence indicated in figure

Reassembly of the airbox - throttle body


If removed, refit the throttle grip cable as indicated: insert the opening cable (m) and the closing cable (h) in the corresponding plate seats (w) on the throttle body (4) as shown in figure.

Note

The throttle cables are distinguished by the writings in different colours on them:

Insert the bolts (t) in the corresponding seats of the pulley. Keep oriented as shown in figure, fasten the cables (m) and (h) inserting the nuts (l).

Tighten the nuts (l) to a torque of 2.5 Nm +/- 10% (sect. 3 - 3, Frame torque settings).

Fit the dust caps (v) on the throttle cable sheaths terminals.

Reassembly of the airbox - throttle body


Reassembly of the airbox - throttle body


Check that the clip (21) of hose (26) is positioned as shown.

Airbox - throttle body
Airbox O-ring Injector Throttle body assembly Screw Clamp Intake manifold Screw Pressure sensor Screw Clamp Hose Sealing washer Intake manifold Sealing washer Scre ...

Refitting the airbox and throttle body
Position the filter box (1). Operate on the vehicle lh side, connect connector (f) of the tps/div motor. Operating on the right side of the vehicle, connect connector (e) from the aps sensor ...

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