Note. See the warnings in Section General information and precautions.
Removing
Relieve the pressure in the fuel tank (see Section Release of residual pressure in the power system), then disconnect the negative cable from the battery.
Models 1.3 l
1. Remove the upper covers of the throttle body and air cleaner (see Section Removing and installing the air cleaner assembly).
2. Disconnect the accelerator cable from the throttle control lever (see Section Removing, installing and adjusting the accelerator cable). Release the cable from the support latch and take it to the side.
3. Disconnect wiring from throttle position module and intake air temperature/pressure sensor.
4. Disconnect the hose coming from the carbon canister and the small vacuum hose coming from the cylinder head cover from the throttle body.
5. After carefully marking the wires, disconnect the electrical connectors. Release the wiring harness from the clips on the top side of the fuel line and take it aside.
6. Disconnect the vacuum hose from the front of the fuel pressure regulator
7. Place an old rag under the fitting connections of the fuel supply and return lines on the fuel line. Release collars and disconnect hoses of lines from the highway. Try to remember the installation position of the hoses - the feeder is located closer to the throttle body.
8. "take a walk" along the vacuum hose from the brake booster servo unit mounted on the bulkhead of the engine compartment to the fitting on the left side of the intake manifold. Remove the hose from the fitting.
9. Unscrew the support post from the right wall of the intake manifold.
10. Make sure that nothing is left connected to the pipeline and does not interfere with its removal.
11. Loosen the six mounting nuts and bolts in several steps (access to four of them is possible from above, to two - from below). Be careful not to confuse the intake manifold mounting with the exhaust manifold mounting. Separate the pipeline from the cylinder head and remove it from the engine compartment - try to prevent fuel residues from escaping from the fuel line. Remove and discard the two gaskets - they must be replaced during assembly without fail.
Models 1.6 l
1. Remove the upper covers of the throttle body and air cleaner (see Section Removing and installing the air cleaner assembly).
2. Disconnect the accelerator cable from the throttle control lever (see Section Removing, installing and adjusting the accelerator cable). Release the cable from the support latch and take it to the side.
3. Disconnect wiring from throttle position module and intake air temperature/pressure sensor. Disconnect the hose coming from the carbon adsorber from the front wall of the throttle body.
4. After carefully marking the wires, disconnect the electrical connectors. Release the wiring harness from the clips on the top side of the fuel line and take it aside.
5. Disconnect the vacuum hose from the fitting on the bottom of the fuel pressure regulator
6. Place an old rag under the fitting connections of the fuel supply and return lines on the fuel line. Release collars and disconnect hoses of lines from the highway. Try to remember the installation position of the hoses - the feeder is located closer to the throttle body.
7. Disconnect the vacuum hose coming from the brake booster servo drive from the fitting on the left wall of the intake manifold.
8. In several stages, loosen and remove the bolts securing the intake manifold to the cylinder head. Separate the pipeline from the head and remove it from the engine compartment - try to prevent fuel residues from flowing out of the fuel line. Remove and discard the two o-rings - they must be replaced on reassembly without fail.
Installation
Installation is in the reverse order. Pay attention to the following points:
- a) Sealing gaskets / rings must be replaced without fail;
- b) All fasteners must be tightened with the required force;
- c) Monitor the quality of all hose and electrical connections;
- d) Don't forget to adjust the accelerator cable (see Section Removing, installing and adjusting the accelerator cable);
- e) Before operating the vehicle, carefully check the power system for signs of leakage.