Removal and installation
1.6L SOCH engines
1. Relieve pressure in the fuel system and remove the ground wire from the battery.
2. Remove the auxiliary drive belt and drain the coolant from the cooling system.
3. Remove the air filter cover and air intake duct.
4. Disconnect the hoses from the throttle body, unscrew the screws and remove the cover from the top of the throttle body.
5. Disconnect the electrical connectors from the throttle potentiometer, idle control motor, fuel injector, coolant temperature sensor, and EGR valve.
6. Remove the alternator mounting bolt on the right side of the manifold.
7. Unscrew the connecting nuts and remove the fuel hoses from the throttle body.
8. Remove the mounting bracket and separate the accelerator torso from the ball joint. Remove the accelerator cable sheath from the bracket.
9. Disconnect the vacuum hose and crankcase ventilation hose from the throttle body.
10. Loosen the clamp and remove the coolant hose from the back of the manifold.
11. Unscrew the union nut and remove the brake booster vacuum hose from the manifold.
12. Check that all hoses are disconnected and unscrew the manifold mounting nuts.
13. Remove the intake manifold.
14. Installation is carried out in the reverse order of removal, it is necessary to install a new intake manifold gasket.
DOCH 1.6L engines
15. Remove the plastic wiring harness bracket at the rear of the intake manifold.
16. Disconnect the electrical connectors from the oxygen sensors, ignition unit, purge valve, and other connectors on the left front side of the manifold. Unscrew the nut securing the ground bar to the cylinder head and manifold.
17. Remove the evaporative emission valve (indicated by an arrow) from the left front end of the manifold and disconnect the valve hose from the manifold.
18. Unscrew the union nut and remove the manifold brake booster vacuum hose. Disconnect the vacuum hose and crankcase ventilation hose from the manifold.
19. Disconnect the vacuum hose from the pressure regulator.
20. Loosen the clamps and remove the hose connecting the throttle body to the top section of the manifold.
21. Unscrew the bolts securing the upper section of the manifold (indicated by arrows). Remove the upper manifold section and gasket.
22. To remove the lower section of the intake manifold, first depressurize the fuel system.
23. Unscrew connecting nuts and disconnect fuel hoses from a fuel highway.
24. Loosen the lower mounting bracket and remove the connecting part from the throttle body.
25. Disconnect the electrical connector from the crankshaft sensor and release it from the manifold.
26. Remove the accelerator torso from the throttle body and disconnect the electrical connectors from the idle control motor and throttle potentiometer.
27. Unscrew the bolts and remove the throttle body.
28. Unscrew the bolts from the tabs of the throttle body bracket and remove the bracket from the manifold.
29. Remove the auxiliary drive belt and unscrew the bolt securing the alternator to the right side of the manifold.
30. Unscrew nuts and remove the bottom section of a collector.
31. Installation is made in sequence, return to removal. In this case, it is necessary to install a new intake manifold gasket, pour coolant into the cooling system and adjust the accelerator torso.
Engines 1.8 and 2.0 l
32. Remove the auxiliary drive belt.
33. Relieve pressure in the fuel system and remove the ground wire from the battery.
34. Disconnect the electrical connectors from the engine intake air temperature sensor and air flow meter.
35. Loosen the clamp and remove the crankcase ventilation hose from the rear of the cylinder head cover.
36. Loosen the clamps and remove the air intake duct from the air filter and throttle body.
37. Remove the mounting bracket and separate the accelerator cable from the throttle cam ball joint.
38. Unscrew the bolts and remove the accelerator cable bracket from the throttle body.
39. Pinch the coolant supply hoses to the rear of the throttle body, loosen the clamps and remove both hoses.
40. Remove the electrical connectors from the throttle potentiometer and idle control ball motor.
41. Mark the location and disconnect the hoses from the throttle body, then unscrew the nuts and remove the throttle body from the intake manifold.
42. Unscrew the connecting nuts and remove the fuel hoses from the fuel line.
43. Disconnect the electrical connectors from the ignition unit, purge valve, manifold valve, coolant temperature sensor, EGR valve, and oxygen sensor.
44. Release the mounting brackets and remove the casing with electrical wires from the rear of the cylinder head. Disconnect the electrical connectors for the crankshaft sensor and knock sensor.
45. Unscrew the union nut and remove the manifold brake booster vacuum hose. Disconnect the vacuum hose and crankcase ventilation hose from the manifold. Disconnect the vacuum hose from the pressure regulator
46. Unscrew the upper alternator mounting bolt on the right side of the intake manifold.
47. Unscrew the bolts and remove the manifold base support bracket.
48. Unscrew the nuts and remove the manifold from the engine.
Installation
Installation is made in sequence, return to removal.
Visitor comments