Early models
Attention: the intake manifold, throttle body, fuel manifold and injectors can be removed and installed as a single unit.
1. If necessary, remove the throttle body, see p.p. 41-43 for late models.
2. If necessary, remove the fuel injectors, see p.p. 44-46 for later models.
3. Disconnect the MAP sensor connectors (1) and knock sensor (2).
4. Remove the knock sensor harness connector from the intake manifold.
5. Lay the wire bundle aside.
6. If the car is equipped with a vacuum brake booster, disconnect the hose strengthen from the fitting at the rear of the intake manifold.
7. Remove the crankcase ventilation hose.
8. Remove the absolute air pressure sensor from the intake manifold (1).
9. Remove the pipe from the fuel vapor accumulator cleaning valve by disconnecting the pipe from the valve (1) and battery tubes (2).
10. Remove the bolt (2) purge valve mounts (3), remove the valve and seal from the intake manifold (1).
11. Turn away bolts of fastening of an inlet collector. When installing, apply sealant to the threads of the mounting bolts and tighten the mounting bolts in the order shown in the figure. Tightening torque: 1st pass 5 Nm; 2nd pass 10 Nm.
12. Remove the intake manifold.
13. Remove the gaskets from the intake manifold (514), discard the pads.
14. Installation is carried out in the reverse order.
Later models
1. Remove the air cleaner outlet duct.
2. Remove the generator.
3. Loosen the nut (1) fixing the engine wire bundle. Tightening torque 5 Nm.
4. Remove the wire bundle holder from the stud.
5. Disconnect the connector (2) fuel vapor accumulator cleaning valve.
6. Disconnect the connector (4) intake manifold absolute pressure sensor.
7. Remove the holder (2) connector of the wire bundle of the left semi-block.
8. Disconnect the connector (1) ignition coils of the left semi-block.
9. Disconnect connector (3) fuel injectors of the left semi-block.
10. Remove clips (4) support for the wire bundle from the studs of the ignition coil bracket of the left semi-block.
Late models, to points 7-10
11. Remove the holder (2) connector of the wiring harness of the right semi-block.
12. Disconnect the connector (1) ignition coils of the right semi-block.
13. Disconnect the connector (3) throttle actuator.
14. Remove clips (4) supporting the wire bundle with the battery charging alternator cable.
15. Remove clips (6) support for the wire bundle from the studs of the ignition coil bracket of the right semi-block.
16. Disconnect the connector (7) fuel injectors of the right semi-block.
17. Remove the bolt (3) fastening clips (1) engine wire harness. Tightening torque 9 Nm.
18. Disconnect the connector (2) coolant temperature sensor.
19. Gather the branches of the wire bundle and tie the wires away from the cowl panel fairing.
20. Remove a clamp of a vacuum hose of the vacuum amplifier of brakes at the amplifier.
21. Remove the vacuum hose from the amplifier fitting.
22. Attach the brake booster vacuum hose to the intake manifold.
23. Disconnect the tube (1) cleaning the fuel vapor accumulator from the cleaning valve.
24. Disconnect the quick connector (2) fuel supply pipes.
25. Remove the crankcase ventilation hose from the intake manifold fitting.
26. Remove the bolts (512) intake manifold mounts.
When installing, tighten the mounting bolts in the order shown in the figure. Tightening torque: 1st pass 5 Nm; 2nd pass 10 Nm.
27. Remove the intake manifold (500).
28. Remove and discard pads (514) intake manifold.
29. Close the intake ports of the cylinder head to prevent dirt from entering the engine cylinders.
30. When replacing the intake manifold, follow the next steps.
31. Lay the intake manifold on a clean workbench.
32. Remove the brake booster vacuum hose clamp from the intake manifold.
33. Remove the vacuum hose from the intake manifold fitting.
34. Turn away a nut of fastening of the top cover of an inlet collector.
35. Remove the intake manifold top cover.
36. Remove the absolute air pressure sensor holder.
37. Remove the absolute air pressure sensor.
38. Disconnect from an inlet collector a tube of system of catching of steams of fuel.
39. Disengage the retainer securing the fuel vapor accumulator cleaning valve to the fuel manifold.
40. Remove the tube and valve for cleaning the fuel vapor accumulator.
41. Remove the bolts (538) and nuts (507) throttle body mounting (508). Tightening torque 10 Nm.
42. Remove the throttle body.
43. Remove and discard throttle body gasket (509).
44. Turn away bolts of fastening of a fuel collector. Tightening torque 10 Nm.
Note: When installing, apply locking adhesive to the bolt threads.
45. Remove the fuel manifold.
Caution: Raise the fuel manifold evenly until all fuel injectors come out of their seats.
46. Remove and discard lower fuel injector o-rings.
Note: Lubricate the NEW O-rings with engine oil when installing.
47. Remove the brake booster vacuum hose fitting.
Attention: when removing the fitting, evenly press the red spacer.
48. Installation is carried out in the reverse order.
Upper intake manifold cover
1. Remove the intake manifold.
2. Perform the operations according to p.p. 32-35 section "Intake manifold. Removal and installation" this chapter.