Dismantling
1. Disconnect "negative" battery terminal.
2. Drain the coolant from the cooling system.
COOLING SYSTEM: MODIFICATION K, volume 1.8, ADJUSTMENTS, Coolant drain, system flushing and filling.
3. Lay out a rag to collect escaping fuel.
4. Disconnect the fuel supply hose from the fuel rail.
CAUTION: Always plug fittings and openings to keep dirt out of the system.
5. Turn away a collar and disconnect an air hose from a throttle branch pipe.
6. Loosen the clamp and disconnect the purge hose from the intake manifold.
7. Turn away a collar and disconnect a hose of ventilation of a crankcase from a throttle branch pipe.
8. Disconnect and remove a hose from an idle speed regulator.
9. Disconnect the connector from the throttle position sensor.
10. Disconnect the connector from the idle speed controller and remove the harness from the clamp.
11. Remove the cover and disconnect the connector from the absolute pressure sensor in the intake manifold (MAP).
12. Remove the throttle control cable from the cable mounting bracket and from the gas sector.
13. Disconnect the ventilation hose from the intake manifold.
14. Press the connector shoulders and disconnect the brake booster vacuum hose from the intake manifold reservoir.
15. Loosen the clamp and disconnect the cooling system hose from the intake manifold.
16. Remove the 3 screws securing the coil cover and remove the cover.
17. Turn away 2 bolts of fastening of 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, 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 collector on the cylinder head, fit the nuts and tighten them to a torque of 17 Nm in the sequence shown in the figure.
4. Attach a hose of system of cooling to a collector and fix it with a collar.
5. Connect the connector to the injector harness and secure the connector to the bracket.
6. Connect the coil connectors, screw in the screws securing the right coil and tighten them to a torque of 10 Nm.
7. Fasten the wire harness of the coil in the clamps.
8. Install the coil cover, screw in the mounting bolts and tighten them to a torque of 10 Nm.
9. Connect the vacuum brake booster hose to the intake manifold.
10. Attach the ventilation hose to the manifold and secure it in the shoulders.
11. Fasten the throttle control cable to the gas sector and the cable sheath to the bracket.
12. Connect the connector to the intake manifold absolute pressure sensor (MAP) and put on the cover.
13. Connect the connector to the idle speed control and secure the harness with a clamp.
14. Attach a hose of an idle speed regulator to a throttle branch pipe.
15. Connect the connector to the throttle position sensor.
16. Attach the crankcase ventilation hose to the throttle body and secure it with a clamp.
17. Attach the adsorber purge hose to the throttle branch pipe and secure it with a clamp.
18. Attach an inlet air hose to a throttle branch pipe and fix it with a collar.
19. Attach the fuel supply hose to the fuel rail.
20. Attach "negative" battery terminal.
21. Fill the cooling system with coolant.
22. Adjust throttle cable.
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