Contents: Dismantling ⇩ Installation ⇩
Dismantling
1. Disconnect the negative battery terminal.
2. Drain the coolant from the cooling system.
COOLING SYSTEM: MODIFICATION K, volume 1.8, ADJUSTMENTS, Draining the coolant, flushing the system and filling.
3. Lay out a rag to collect any leaking fuel.
4. Disconnect the fuel supply hose from the fuel rail.
CAUTION: Always plug the fittings and holes to protect the system from dirt.
5. Loosen the clamp and disconnect the air hose from the throttle body.
6. Loosen the clamp and disconnect the purge hose from the intake manifold.
7. Loosen the clamp and disconnect the crankcase ventilation hose from the throttle body.
8. Disconnect and remove the hose from the idle air control valve.
9. Disconnect the connector from the throttle position sensor.
10. Disconnect the connector from the idle speed control valve and remove the harness from the clamp.
11. Remove the cover and disconnect the connector from the manifold absolute pressure (MAP) sensor.
12. Remove the throttle control cable from the cable mounting bracket and from the throttle sector.
13. Disconnect the ventilation hose from the intake manifold.
14. Press the connector shoulders and disconnect the brake booster hose from the intake manifold receiver.
15. Loosen the clamp and disconnect the coolant hose from the intake manifold.
16. Unscrew the 3 screws securing the coil cover and remove the cover.
17. Unscrew the 2 bolts securing the right coil and remove the coil.
18. Disconnect the connector from the coil and remove the coil harness from the clamps.
19. Release the injector harness connector from the bracket and disconnect the connector.
20. In the sequence shown in the figure, loosen and unscrew the 7 nuts securing the intake manifold to the cylinder head.
21. Remove the intake manifold and discard its gaskets.
Installation
1. Check that the mating surfaces of the manifold and cylinder head are clean and that metal spacers are installed in the sockets for the studs and bolts.
2. Install a new gasket on the intake manifold.
CAUTION: Gaskets must be installed dry.
3. Install the manifold on the cylinder head, tighten the nuts and tighten them to 17 Nm in the sequence shown in the figure.
4. Connect the cooling system hose to the manifold and secure it with a clamp.
5. Connect the connector to the injector harness and secure the connector to the bracket.
6. Connect the coil connectors, screw in the right coil mounting bolts and tighten them to 10 Nm.
7. Secure the coil wiring harness to the clamps.
8. Install the coil cover, screw in the mounting bolts and tighten them to a torque of 10 Nm.
9. Connect the brake booster hose to the intake manifold.
10. Attach the ventilation hose to the manifold and secure it in the shoulders.
11. Secure the throttle control cable to the throttle sector and the cable housing to the bracket.
12. Connect the connector to the manifold absolute pressure (MAP) sensor and install the cover.
13. Connect the connector to the idle speed control valve and secure the harness with a clamp.
14. Connect the idle air control hose to the throttle body.
15. Connect the connector to the throttle position sensor.
16. Connect the crankcase ventilation hose to the throttle body and secure it with a clamp.
17. Connect the purge hose of the adsorber to the throttle pipe and secure it with a clamp.
18. Connect the air intake hose to the throttle body and secure it with a clamp.
19. Connect the fuel supply hose to the fuel rail.
20. Connect the negative battery terminal.
21. Fill the cooling system with coolant.
22. Adjust the throttle control cable.
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