Contents: Fuel line and injectors ⬇ Pressure regulator ⬇ Idle speed control motor ⬇ Throttle potentiometer ⬇ Coolant temperature sensor ⬇ Engine Air Intake Temperature Sensor ⬇ Manifold Absolute Pressure Sensor ⬇ Crankshaft sensor ⬇ Camshaft sensor ⬇ Knock sensor ⬇ Electronic control device ⬇ Fuel pump relay ⬇
Fuel line and injectors
Removal and installation
1. Relieve pressure in the fuel system. Remove the ground wire from the battery.
2. Remove the upper section of the intake manifold.
3. Disconnect the electrical connectors from the four fuel injectors and remove the wiring harness from the fuel line.
4. Unscrew the union nuts and disconnect the fuel hoses from the fuel line.
5. Remove the three bolts and remove the fuel line and injectors from the intake manifold. Remove the lower sealing rings from the fuel injectors.
6. Release the retaining clips and remove the fuel injectors from the fuel line. Remove the upper O-rings from the fuel injectors.
7. Installation is performed in the reverse order of removal. In this case, new sealing rings must be installed on the fuel injectors.
Pressure regulator
Removal and installation
1. Relieve the pressure in the fuel system and remove the ground cable from the battery.
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2. To improve access to the fuel rail, remove the harness bracket from the intake manifold. On 1.6L DOCH engines, the pressure regulator is located on the left front end of the fuel rail.
3. While holding the regulator with a wrench, unscrew the fuel supply hose union nut. Disconnect the fuel supply hose and vacuum hose from the regulator.
4. Remove the bolts and remove the electrical wire bracket from the fuel line.
5. Remove the regulator from the end of the fuel line together with the sealing ring.
6. Installation is performed in the reverse order of removal. In this case, it is necessary to use a new sealing ring.
Idle speed control motor
Removal and installation
1. To access the idle speed control motor, remove the throttle body.
2. Unscrew the screws (indicated by arrows) and remove the idle speed control motor together with the sealing rings.
3. Installation is performed in the reverse order of removal. Before installing the engine, check that the plunger end protrudes from the engine body by no more than 33 mm.
Throttle potentiometer
Removal and installation
1. Remove the throttle body.
2. Unscrew the screws (indicated by arrows) and remove the potentiometer from the throttle.
3. When installing the potentiometer, make sure it is properly aligned with the throttle shaft.
Coolant temperature sensor
The coolant temperature sensor is screwed into the thermostat housing.
Engine Air Intake Temperature Sensor
The temperature sensor is installed in the intake duct that connects the air filter housing to the intake manifold.
Removal and installation
1. Turn off the ignition and disconnect the electrical connector from the sensor.
2. Remove the sensor and remove the sealing ring from the intake port.
3. Installation is carried out in the reverse order of removal.
Manifold Absolute Pressure Sensor
The absolute pressure sensor in the intake manifold is installed on the bulkhead of the engine compartment on the left side of the intake manifold.
Removal and installation
1. Turn off the ignition and remove the electrical connector and vacuum hose from the sensor. Remove the sensor.
2. Installation is carried out in the reverse order of removal.
Crankshaft sensor
The sensor is mounted on the rear of the cylinder block and is accessible from underneath the vehicle.
Removal and installation
1. Raise the front of the vehicle and support it on stands.
2. Remove the sensor electrical wiring from the mounting brackets and disconnect the sensor electrical connector.
3. Unscrew the bolt and remove the sensor.
4. Installation is carried out in the reverse order of removal.
5. Using a feeler gauge blade, check that the gap between the end of the sensor and the teeth of the crankshaft pulley is 1±0.7 mm.
Camshaft sensor
1. Remove the upper timing belt cover.
2. Release the sensor wiring from the mounting brackets and disconnect the electrical connector.
3. Unscrew the bolts and remove the sensor from the cylinder head.
4. Installation is carried out in the reverse order of removal.
Knock sensor
The knock sensor is mounted on the rear of the cylinder block and is accessible from underneath the vehicle.
Removal and installation
1. Raise the front of the vehicle and support it on stands.
2. Disconnect the sensor electrical connector located on the sensor wires.
3. Unscrew the bolt and remove the sensor from the engine.
4. Check that the mating surfaces of the sensor and the cylinder block are clean and dry, install the sensor, secure it with a bolt and connect the electrical connector.
Electronic control device
The ECU is located under the water deflector in front of the windshield.
Removal and installation
1. Remove the ground cable from the battery. Remove the wiper arms.
2. Remove the upper seal from the engine compartment bulkhead and remove the water deflector.
3. Unscrew the nuts and remove the protective cover of the ECU unit.
4. Disconnect the electrical connectors, unscrew the nuts and remove the ECU unit.
5. Installation is carried out in the reverse order of removal.
Fuel pump relay
The fuel pump relay is located in the engine compartment in the relay block.
Removal and installation
1. Remove the relay box cover and remove the fuel pump relay which is colored purple.
2. Installation is carried out in the reverse order of removal.
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