Note: Before starting the procedure, refer to the warning in paragraph 1.
Withdrawal
1. Disconnect the wire from the battery "masses", as described in chapter 5A.
2. If provided, remove the engine top cover.
3. Drain the liquid from the cooling system. as described in chapter 1A. On non-turbocharged models, clamp the system hoses leading to the throttle body with suitable clamps.
4. If the coolant drains. loosen the clamps and disconnect the two hoses from the expansion tank, mounted to the left of the engine.
5. Turn away screws of fastening and lift a broad tank. Disconnect the wiring from the emergency fluid level sensor. Remove the tank from the car. If you will not drain the fluid, move the reservoir to the rear of the engine compartment away from the intake manifold.
6. Disconnect the accelerator cable from the throttle body and mounting bracket as described in paragraph 3.
7. On models with cruise control, disconnect the actuator rod from the throttle body.
8. Disconnect the vacuum hose from the canister purge valve on the intake manifold.
9. Disconnect the brake booster vacuum hose from the intake manifold
10. On non-turbo models, remove the intake duct between the throttle body and air filter and also, if necessary, disconnect the crankcase ventilation hose. Remove the air duct from under the hood.
11. On turbocharged models, disconnect the intake duct from the throttle body to the left of the engine
12. Disconnect the fuel pressure regulator wiring and hose from the throttle body. Loosen the clamps and disconnect the coolant hoses from the throttle body Remove the throttle body from the intake manifold as described in paragraphs 4 or 5.
13. On ADR and AFY engines built before 07/1997, disconnect the wiring from the air temperature sensor.
14. On ADR and AFY engines manufactured after 08/1997, disconnect the wiring from the air temperature sensor and the intake manifold switching valve.
15. Turn away bolts of fastening of a fuel stage and remove it together with atomizers from an inlet collector, having laid down in a back part of engine compartment on a pure rag. On ADR engines. AFY, AHL, AEB and AJL also disconnect the wiring from the Hall sensor in front of the engine.
16. On ADP engines, dismantle the upper tube of the cooling system from above the intake manifold, loosen the clamps and disconnect the hoses from both sides of the tube. Remove the tube from the engine.
17. On AEB and AJL engines, disconnect the hoses from the top tube of the cooling system. remove the pipe from the intake manifold and the flange at the rear of the cylinder head.
18. Turn away a bolt and nuts of fastening of arms of support to an inlet collector. Loosen the nuts from the rubber mounts (pic. 10.18, a, b).
19. Remove the oil dipstick. On ADR engines, note the position of the coolant hose between the center passages of the intake manifold (pic. 10.19, a, b).
20. Turn away nuts, bolts of fastening of an inlet collector to a head of cylinders. Remove manifold, gasket (pic. 10.20 a-c).
Installation
21. Installation is the reverse procedure of removal. taking into account the following.
- A) Make sure the mating surfaces are clean and dry and install a new gasket.
- b) Install the manifold by tightening its fastening nuts evenly and gradually to the prescribed torque.
- V) Check and, if necessary, adjust the accelerator cable - see paragraph 3.
- G) Add fluid to the cooling system as described in chapter 1A.
- d) Connect battery - see chapter 5A.
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