MODULAR INLET MANIFOLD - R+R

Operation 1072D10 · MODULAR INLET MANIFOLD (V.I.S.)

2.0 JTS

Removing

Position the vehicle on a lift.

PROCEED WITH DRAINING THE HIGH PRESSURE FUEL SYSTEM FOLLOWING THE INSTRUCTIONS GIVEN BELOW.

Start the engine.

Keep the engine idling for 2 minutes.

Detach the fuel pump relay.

Wait until the engine cuts out.

Try and start the engine: if the engine starts within 10 seconds wait for it to cut out, then try and start the engine again; if the engine does not start within 10 seconds, continue for another 5 seconds.

Wait for the engine to cool down.

Make sure that the ignition key is in the OFF position, then disconnect the negative battery terminal (-)

Proceed with the removal

Op. 1016A40 IGNITION COIL COVER ON CYLINDER HEAD- R+R.

Proceed with the removal

Op. 7055B54 UNDER-ENGINE GUARD - R R.

Proceed with the removal

Op. 1076B18 RIGID SECTION OF EXHAUST PIPE BETWEEN CATALYTIC CONVERTER AND SILENCER - R + R.

1. Undo the bolts (1a) and (1b) and remove the modular intake manifold mounting bracket (1c) after having released the bands from the electrical wiring.

Proceed with the removal

Op. 1048A59 PIPE from flow meter to throttle casing hose - R.R..

Proceed with the removal

Op. 5530B10 BATTERY - R+R.

1. Disconnect the electrical connection from the throttle casing integrated with D.V.L. and release the electrical wiring from the band.

1. Disconnect the electrical connection for the fuel pressure regulator.

2. Disconnect the electrical connection from the fuel pressure sensor.

1. Disconnect the electrical connection from the phase transformer solenoid.

2. Disconnect the electrical connection from the switching control actuator enablement solenoid valve.

3. Disconnect the electrical connection for the cam angle sensor.

1. Disconnect the engine wiring electrical connections (1a) and (1b).

2. Loosen the band and disconnect the oil vapour recirculation pipe from the modular intake manifold.

3. Loosen the band and disconnect the vacuum intake pipe from the modular intake manifold.

1. Disconnect the rapid connector for the fuel supply pipe and release it from the fastening on the modular intake manifold.

2. Disconnect the rapid connector for the fuel vapour recovery pipe.

1. Disconnect the vacuum intake pipe from the air flow switching device actuator and release it from the fastening on the latter.

2. Disconnect the air flow switching device actuator linkage.

3. Undo the bolts (3a) and remove the air flow switching device control actuator (3b).

1. Undo the bolts (1a) and move the power assisted steering fluid reservoir (1b) sideways.

1. Loosen the band and disconnect the flexible section from the rigid section of the coolant return pipe to the engine coolant reservoir.

1. Release the rigid coolant return pipe to the engine coolant reservoir from the fastenings on the modular intake manifold and move it to the side.

1. Undo the bolts (1a) and remove the throttle casing with D.V.L. (1b).

2. Remove the O-ring.

1. Undo the fuel pressure sensor and remove it.

Undo the bolts fixing the brackets connecting the modular intake manifold to the intake manifold, intake manifold side.

1. Loosen the bands fixing the inlet hoses, modular intake manifold side.

2. Retract the modular intake manifold, releasing it from the intake hoses.

3. Loosen the remaining bands (3a) and remove the inlet hoses (3b).

Move the modular intake manifold towards the ABS hydraulic unit.

1. Undo the bolts (1a) fixing the brackets (1b) connecting the modular intake manifold to the intake manifold, modular intake manifold side and remove them.

1. Lift up the modular intake manifold as necessary to disconnect the electrical connection for the fuel vapour solenoid valve.

2. Remove the modular intake manifold.

Refitting

Place the modular intake manifold in position after having connected the electrical connection to the fuel vapour solenoid valve.

Place the connecting brackets for the modular intake manifold and the intake manifold in position and secure them to the modular intake manifold using the bolts.

Place the inlet hoses in position and secure them to the intake manifold using the bands.

Place the modular intake manifold in position and connect it to the inlet hoses.

Tighten the bands fixing the inlet hoses, modular intake manifold side.

Tighten the bolts fixing the brackets connecting the modular intake manifold to the intake manifold, intake manifold side.

1. Place the fuel pressure sensor in position and tighten it to the recommended torque.

1. Place the O-ring in position.

2. Place the throttle casing integrated with D.V.L. (2a) in its housing and secure it by tightening the bolts (2b) to the recommended torque.

Connect the vacuum intake pipe to the modular intake manifold and tighten the band.

Connect the oil vapour recirculation pipe to the modular intake manifold and tighten the band.

Place the rigid coolant return pipe to the engine coolant reservoir in position and secure it to the modular intake manifold.

Connect the flexible section of the coolant return pipe to the engine coolant reservoir to the rigid section and tighten the band.

Place the power assisted steering fluid reservoir in its housing and secure it using the bolts.

Place the air flow switching device control actuator back in its housing and secure it using the bolts.

Connect the air flow switching device actuator linkage.

Connect the vacuum intake pipe to the air flow switching device actuator and secure it to the fastening on the latter.

Connect the rapid connector for the fuel vapour recovery pipe.

Cconnect the rapid connector for the fuel supply pipe and secure it to the modular intake manifold.

Connect the electrical connections for the engine wiring.

Connect the electrical connection for the cam angle sensor.

Connect the electrical connection to the switching control actuator enablement solenoid valve.

Connect the electrical connection to the phase transformer solenoid.

Connect the electrical connection to the fuel pressure sensor.

Connect the electrical connection to the fuel pressure regulator.

Connect the electrical connection to the throttle casing integrated with D.V.L. and fasten the wiring to the band.

Proceed with the refitting

Op. 1048A59 PIPE from flow meter to throttle casing hose - R.R..

Proceed with the refitting

Op. 5530B10 BATTERY - R+R.

Place the modular intake manifold mounting bracket in position and secure it using the bolts, then fasten the electrical wiring to the bands.

Proceed with the refitting

Op. 1076B18 RIGID SECTION OF EXHAUST PIPE BETWEEN CATALYTIC CONVERTER AND SILENCER - R + R.

Proceed with the refitting

Op. 7055B54 UNDER-ENGINE GUARD - R R.

Proceed with the refitting

Op. 1016A40 IGNITION COIL COVER ON CYLINDER HEAD- R+R.

Connect the negative battery terminal (-).

Remove the vehicle from the lift.

1.8 T.SPARK

Removing

• Position the vehicle on a lift.
• Make sure that the ignition key is in the OFF position, then disconnect the battery terminal (-).

• Undo the bolts fixing the mounting bracket to the modular intake manifold.

• Op. 1016A40 COPERCHIO BOBINE ACCENSIONE SU TESTA CILINDRI - S.R.

1. Disconnect the electrical connection from the air flow meter.

• Release the electrical wiring for the air flow meter from the fastening on the air intake hose.

2. Disconnect the air intake hose from the filter.

3. Disconnect the oil vapour recovery pipes from the tappet cover.

4. Disconnect the air intake hose from the throttle casing integrated with D.V.L.

5. Remove the air inlet hose (5a) complete with air flow meter (5b) and oil vapour recovery pipe (5c).

• Op. 1056B60 TUBO COLLETTORE COMBUSTIBILE UNICO, COMPLETO DI ELETTROINIETTORI - S.R.

1. Disconnect the electrical connection from the engine coolant temperature sensor.

2. Undo the nut (2a) and disconnect the earth lead (2b) from the intake manifold.

1. Disconnect the electrical connection from the throttle casing integrated with D.V.L. and release the wiring from the band.

2. Disconnect the electrical connections (2a) and (2b) from the injection/ignition control unit.

3. Undo the bolt (3a) and disconnect the earth lead (3b) from the injection/ignition control unit mounting.

1. Disconnect the engine front coupling.

• Release the electrical wiring for the engine rpm sensor from the fastening band.

2. Disconnect the electrical connection for the detonation sensor.

3. Disconnect the electrical connection for the Lambda sensor.

4. Disconnect the electrical connection for the cam angle sensor.

1. Disconnect the electrical connection from the switching control actuator enablement solenoid valve.

• Release the electrical wiring from the modular intake manifold.

2. Disconnect the rapid connector for the fuel vapour recovery pipe.

Seal the fuel vapour recovery system pipes.

3. Release the fuel vapour recovery pipe from the fastening on the power assisted steering fluid reservoir.

1. Undo the bolts (1a) and move the power assisted steering fluid reservoir (1b) without disconnecting the pipes.

2. Disconnect the coolant return pipe from the engine coolant reservoir, reservoir side.

Collect the coolant that comes out, then seal the pipes to prevent impurities from getting into the system.

3. Release the rigid coolant return pipe to the engine coolant reservoir from the fastenings on the modular intake manifold and move it.

1. Undo the bolts (1a) and remove the support (1b) complete with injection/ignition control unit (1c).

The above bolts also secure the throttle casing integrated with D.V.L. to the modular intake manifold.

2. Undo the remaining bolt (2a) and remove the throttle casing with D.V.L. (2b).

• Disconnect the brake servo vacuum intake pipe from the modular intake manifold.
• Disconnect the electrical connection from the fuel vapour solenoid valve.

• Loosen the bands fixing the hoses to the intake manifold.
• Undo the bolts (2a) and remove the modular intake manifold (2b) after having released the electrical wiring from the fastenings.

• Place the modular intake manifold in its housing and secure it using the bolts.
• Tighten the bands fixing the hoses to the intake manifold.
• Connect the electrical connection to the fuel vapour solenoid valve.
• Connect the brake servo vacuum intake pipe to the single-acting valve.

• Place the throttle casing integrated with D.V.L. (1a) in its housing and secure it temporarily using the bolt (1b).
• Place the mounting (2a), complete with injection/ignition control unit (2b), back in its housing and secure it tightening the bolts (2c) to the recommended torque.

The above bolts secure both the throttle casing and the control unit mounting.

• Place the coolant return pipe to the engine coolant reservoir in position and secure it using the bands on the air chamber.
• Connect the coolant return pipe to the engine coolant reservoir.
• Place the power assisted steering fluid reservoir in its housing and secure it using the bolts.
• Connect the rapid connector for the fuel vapour recovery pipe.
• Secure the fuel vapour recovery pipe to the fastening on the power assisted steering fluid reservoir.
• Connect the electrical connection to the switching control actuator enablement solenoid valve.
• Connect the electrical connection for the cam angle sensor.
• Connect the electrical connection for the Lambda sensor.
• Connect the electrical connection for the detonation sensor.
• Secure the electrical wiring for the engine rpm sensor using the fastening band.
• Connect the engine front coupling.
• Connect the earth lead to the injection/ignition control unit mounting and secure it using the bolt.
• Connect the electrical connections to the injection/ignition control unit.
• Connect the electrical connection to the throttle casing integrated with D.V.L. and fasten the wiring to the band.
• Connect the earth lead to the intake manifold and secure it using the nut.
• Connect the electrical connection to the engine coolant temperature sensor.
• Fasten the electrical wiring to the modular intake manifold.
• Op. 1056B60 TUBO COLLETTORE COMBUSTIBILE UNICO, COMPLETO DI ELETTROINIETTORI - S.R.
• Place the air intake hose complete with air flow meter back in its housing and connect it to the air filter and to the throttle casing integrated with D.V.L.
• Connect the oil vapour recovery pipes to the tappet cover.
• Connect the electrical connection for the air flow meter and fasten the wiring to the air intake hose.
• Op. 1016A40 IGNITION COIL COVER ON CYLINDER HEAD- R+R
• Tighten the bolts fixing the mounting bracket to the modular intake manifold.
• Connect the negative battery terminal (-).
• Remove the vehicle from the lift.