Contents: Throttle body ⬇ Fuel injector ⬇ Inlet air temperature sensor ⬇ Fuel pressure regulator ⬇ Throttle Position Unit ⬇ Throttle potentiometer ⬇ Idle switch ⬇ Lambda sensor ⬇ Coolant temperature sensor ⬇ Electronic Control Unit (ECU) ⬇ Fuel Pump Relay and Fuse ⬇
Note: When working with fuel system components, follow the precautions given in Chapter 1.
Throttle body
Removal
1. Guided by Chapter 2, remove the air filter housing.
2. Guided by Chapter 9, depressurize the fuel system, then connect the negative battery cable.
3. Disconnect the fuel hoses from the channels on the side of the throttle body. The arrows indicate the direction of fuel flow (and there are marks on the hoses) (see illustrations).
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4. Disconnect the wiring harnesses from the connector on the throttle body, mark them so as not to mix them up during installation (see illustration).
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5. Guided by Chapter 4, disconnect the throttle cable from the throttle body.
6. Loosen and remove the four pinch bolts securing the throttle body to the intake manifold (see illustration). Lift the throttle body, remove the gasket (where is available). It is not recommended to separate the upper and lower halves of the throttle body unless necessary - they are held together by two internal tie bolts. If separated, use a new gasket when reassembling.
Installation
7. Installation is carried out in reverse order; replace all gaskets. Tighten the clamping bolts. Finally, check and, if necessary, adjust the throttle cable.
Fuel injector
Removal
8. Guided by Chapter 2, remove the air filter housing.
9. Guided by Chapter 9, depressurize the fuel system, then disconnect the negative battery cable.
10. Disconnect the wiring harnesses from the connector on the injector, mark them to avoid confusion during installation.
11. Loosen the screw and lift up the injector/intake air temperature sensor housing (see illustration). Remove the gasket.
12. Loosen the retaining washer, then remove the injector from the throttle body, removing the O-ring (see illustration).
5.12. Upper half of the throttle body, showing the injector mounting hardware
1. Upper part of the throttle body; 2. Fuel pressure regulator; 3. O-ring seal; 4. Fastening washer; 5. Gasket; 6. Screw for fixing the injector/intake air temperature sensor; 7. Inlet air temperature sensor; 8. Fuel injector; 9. Fuel supply pipe; 10. Gasket between the upper and lower parts of the throttle body; 11. Fuel return pipe; 12. Compaction.
13. Use a multimeter to check the electrical resistance of the injector and compare the result with the data in Specifications.
Installation
14. Installation is carried out in the reverse order of removal. Replace all O-rings and gaskets. Apply a suitable sealant to the screw threads, then insert and tighten the fastening screw to the specified tightening torque Specifications.
Inlet air temperature sensor
15. The inlet air temperature sensor is an integral part of the injector mounting cover. Its removal is described in the previous subchapter.
Fuel pressure regulator
Removal
16. If the fuel pressure regulator operation is being checked, disassemble the unit as described below and check that the internal components are clean and undamaged.
Note: The fuel pressure regulator components are factory fitted to the upper throttle body. If the pressure regulator is faulty, we recommend replacing the upper throttle body. Consult your parts supplier.
17. Remove the air filter housing, following the Chapter 2.
18. Guided by Chapter 9, depressurize the fuel system, then disconnect the negative battery cable.
19. Referring to the relevant sub-chapter, loosen the screw and lift the inlet air temperature sensor/nozzle cover.
20. Loosen and remove the three mounting screws, lift up the fuel pressure regulator mounting frame.
21. Lift the top cover, spring and membrane.
22. Clean all components thoroughly, then inspect the membrane for cracks or other damage.
Installation
23. Install the pressure regulator in the reverse order of removal.
Throttle Position Unit
Removal
24. Disconnect the negative battery cable. Remove the air cleaner housing, following the Chapter 2.
25. Guided by Chapter 4, disconnect the throttle cable from the throttle body.
26. Disconnect the wiring connector from the throttle position module.
27. Unscrew the mounting screws (see illustration), and remove the block (together with the throttle cable mounting bracket) from the throttle body.
Installation
28. Installation is carried out in reverse order. Please note that if a new unit has been installed, the idle switch adjustment must be checked - consult your dealer as this work requires access to test equipment.
Throttle potentiometer
29. Referring to the appropriate sub-chapter, remove the throttle body. The throttle potentiometer is mounted in the lower part of the throttle body and cannot be replaced separately.
Idle switch
30. Referring to the appropriate subchapter, remove the throttle position unit. The idle switch is built into this unit and cannot be replaced separately.
31. If a new throttle position unit has been installed, the idle air switch adjustment must be checked - consult your dealer as this work requires access to test equipment.
Lambda sensor
Removal
32. The lambda sensor is screwed into the exhaust pipe, before the catalytic converter (see illustration).
33. Disconnect the negative battery cable. Disconnect the wiring harness from the connector mounted in the bracket on the transmission.
34. Working underneath the vehicle, loosen and remove the sensor, being careful not to damage the tip.
Installation
35. Apply a small amount of anti-blocking material to the sensor threads.
36. Install the sensor on the housing, tighten it with the correct tightening torque. Reconnect the wiring harness. Please note that the type of Lambda sensor installed depends on the vehicle specification - sensors are not interchangeable and cannot be used from another model.
Coolant temperature sensor
Removal
37. The coolant temperature sensor of the Control System is screwed into the intake manifold (do not confuse it with the temperature gauge sensor). If the sensor fails, the engine runs unstably during warm-up.
38. The resistance of the hot sensor should be about 2 kOhm, and the cold sensor - about 300 Ohm.
39. To replace the sensor, disconnect one of the hoses and drain the coolant from the manifold. Plug the hole in the manifold.
40. Disconnect the wiring and unscrew the sensor.
Installation
41. Screw the sensor into place using a new gasket.
42. Connect the electrical wiring and add coolant.
Electronic Control Unit (ECU)
43. The ECU is mounted in the left side of the engine compartment. The unit is coded and should not be removed without consulting a dealer, otherwise it may not function properly after the multi-pin connector is reconnected.
Fuel Pump Relay and Fuse
44. The pump relay and fuse are mounted in a block located in the vehicle interior.
45. The relay is located in position 5 on the relay board and is powered through fuse 4.
46. Remove the relay from the socket, remembering its location.
47. Please note that when the fuse in the engine management system is removed, the accumulated information is lost (as when disconnecting the battery). To "train" the system before driving, it is necessary to let the engine idle for a few minutes.