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19FUEL SYSTEM
2
REPAIR COOLANT TEMPERATURE SENSOR
Service repair no - 18.30.10
Remove
1.Position drain tin below coolant pump hose.
2.Disconnect sensor multiplug.
3.Release harness clip and harness.
4.Remove sensor.
Refit
5.Clean sensor.
6.Fit sensor and tighten to the correct torque.
7.Position harness and secure with clip.
8.Connect multiplug.
9.Top-up cooling system.CRANKSHAFT SENSOR
Service repair no - 18.30.12
Remove
1.Position vehicle on ramp [hoist].
2.Disconnect multiplug from crankshaft sensor
flylead.
3.Remove screw, release lead from bracket.
4.Raise ramp [hoist].
5.Remove 2 bolts securing crankshaft sensor.
6.Remove crankshaft sensor.
Refit
7.Clean crankshaft sensor and mating surface of
backplate.
8.Fit crankshaft sensor, fit bolts. Tighten to
7Nm
9.Lower vehicle.
10.Position lead to bracket, fit and tighten screw.
11.Connect multiplug
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Mpi
3
REPAIR FUEL TEMPERATURE SENSOR
Service repair no - 18.30.08
Remove
1.Disconnect fuel temperature sensor multiplug.
2.Remove fuel temperature sensor.
3.Discard sealing washer.
Refit
4.Clean mating face of fuel rail.
5.Fit a new sealing washer to sensor.
6.Fit temperature sensor. Tighten to
7Nm
7.Connect fuel temperature sensor multiplug.MEMS ENGINE CONTROL MODULE (ECM)
Service repair no - 18.30.01
Remove
1.Remove 3 bolts securing ECM.
2.Disconnect 2 multiplugs from ECM.
3.Disconnect vacuum hose from ECM.
4.Remove ECM.
5.Collect ECM spacers (LHD only)
Refit
6.Position ECM and spacers to wing [fender].
7.Connect vacuum hose to ECM.
8.Connect multiplugs to ECM.
9.Position ECM to mounting.
10.Fit bolts and tighten.
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19FUEL SYSTEM
4
REPAIR CHARCOAL CANISTER
Service repair no - 17.15.13
Remove
1.Disconnect multiplug from purge valve.
2.Release clip and disconnect hose from purge
valve.
3.Release clip and disconnect fuel tank hose from
charcoal canister.
4.Unscrew bolt to release securing strap and
remove charcoal canister.
Refit
5.Fit charcoal canister and secure strap.
6.Connect fuel tank hose to charcoal canister and
secure clip.
7.Connect hose to purge valve and secure clip.
8.Connect multiplug to purge valve.THROTTLE CABLE
Service repair no - 19.20.06
Remove
1.Loosen 2 nuts securing throttle cable to
abutment bracket.
2.Release throttle cable from throttle lever.
3.Remove footwell closing panel.
4.Release split [cotter] pin from throttle pedal
clevis pin.
5.Remove clevis pin and release cable from
throttle pedal.
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Mpi
5
REPAIR 6.Remove nut securing throttle cable bracket to
brake servo and release cable.
7.Release grommet from bulkhead and withdraw
cable.
8.Locate cable in bulkhead.
9.Connect cable to throttle pedal.
10.Connect cable to cam.
11.Adjust throttle cable.THROTTLE POTENTIOMETER
Service repair no - 19.22.49
Remove
1.Disconnect throttle potentiometer multiplug.
2.Remove 2 screws securing throttle
potentiometer, remove potentiometer.
Refit
3.Clean mating faces of throttle potentiometer and
throttle housing.
4.Fit throttle potentiometer, fit and tighten screws.
CAUTION: Ensure throttle potentiometer is
correctly engaged with throttle cam and
that wiring outlet faces downwards.
5.Connect multiplug.
6.Check with diagnostic equipment.
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19FUEL SYSTEM
6
REPAIR INTAKE AIR TEMPERATURE SENSOR
Service repair no - 18.30.09
Remove
1.Disconnect multiplug from temperature sensor.
2.Remove sensor from inlet manifold.
Refit
3.Clean sensor threads and mating face.
4.Fit sensor to inlet manifold. Tighten to
7Nm
5.Connect multiplug to sensor.PURGE CONTROL VALVE
Service repair no - 17.15.39
Remove
1.Disconnect multiplug from purge control valve.
2.Release clip and disconnect hose from valve.
3.Release valve from charcoal canister.
4.Remove valve.
5.Discard 'O' ring.
Refit
6.Clean valve and valve location.
7.Position and secure valve to charcoal canister.
8.Connect hose to purge valve and secure with
clip.
9.Connect multiplug to valve.
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Mpi
7
REPAIR FUEL RAIL AND INJECTORS
Service repair no - 19.60.04 - Rail
Service repair no - 19.60.10 - Injectors
Remove
1.Remove inlet manifold chamber gasket.
See
MANIFOLD AND EXHAUST SYSTEM, Repair,
Manifold Chamber Gasket - Mpi
2.Remove pressure regulator.
3.Remove 4 bolts securing fuel feed hose flange
stiffening bracket, remove stiffening bracket.
4.Release fuel feed hose from fuel rail.
5.Discard 'O' ring.
6.Disconnect 4 injector multiplugs.
7.Move injector harness aside.
8.Remove 2 bolts securing fuel rail to inlet
manifold.
9.Release 4 injectors from inlet manifold.
10.Remove fuel rail complete with injectors.
11.Discard outlet 'O' rings from injectors.
12.Fix protective cap to each injector.
Do not carry out further dismantling if component
is removed for access only.
13.Remove clip(s) securing injector(s) to fuel rail.
14.Remove injector(s).
15.Discard inlet 'O' ring(s) from injector(s).
16.Remove fuel temperature sensor.
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19FUEL SYSTEM
8
REPAIR Refit
17.Clean fuel rail, temperature sensor and pressure
regulator mating surfaces.
18.Fit fuel temperature sensor. Tighten to
7Nm
19.Clean injectors and injector recesses in fuel rail
and inlet manifold.
20.Fit new 'O' ring(s) to inlet end of injector(s).
21.Fit injector(s) to fuel rail, fit and secure clip(s).
22.Fit new 'O' rings to outlet ends of injectors.
23.Align injectors to inlet manifold and push fuel rail
into position.
24.Fit fuel rail securing bolts. Tighten to
10 Nm
25.Connect injector multiplugs.
26.Remove plugs from fuel feed hose and fuel rail.
27.Fit new 'O' ring to fuel feed hose.
28.Connect fuel feed hose to fuel rail.
29.Fit stiffening bracket.
30.Tighten stiffening bracket and feed hose bolts.
31.Fit pressure regulator.
32.Fit inlet manifold chamber.THROTTLE HOUSING
Service repair no - 19.22.45
Remove
1.Loosen clip, disconnect hose from throttle
housing.
2.Disconnect multiplug from stepper motor.
3.Disconnect multiplug from throttle potentiometer.
4.Disconnect breather hose from throttle housing.
5.Loosen 2 nuts securing throttle cable to
abutment bracket and release cable.
6.Release throttle cable from cam.
7.Remove 4 nuts securing throttle housing to
flexible mounting.
8.Release throttle housing from studs.
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Mpi
9
REPAIR
Refit
9.Examine flexible mounting for splits or damage;
renew as necessary.
10.Thoroughly clean throttle housing and mating
face of flexible mounting.
11.Connect breather hose to throttle housing.
12.Position throttle housing to mounting studs, fit
nuts. Tighten to
7 Nm.
13.Connect throttle cable to cam.
14.Adjust throttle cable.
15.Connect multiplug to stepper motor.
16.Connect multiplug to throttle potentiometer.
17.Connect hose to throttle housing, tighten clip.FUEL PRESSURE REGULATOR
Service repair no - 19.45.06
Remove
1.Disconnect battery negative lead.
2.Position absorbant cloth around fuel pipe to fuel
rail union. Loosen bolt to relieve pressure.
Re-tighten bolt.
3.Release clip and disconnect fuel hose from
pressure regulator.
CAUTION: Plug the connectors.
4.Disconnect intake air temperature sensor
multiplug.
5.Remove 4 bolts securing pressure regulator
steady bracket to fuel rail and manifold, remove
steady bracket.
6.Disconnect vacuum hose from pressure
regulator.
7.Manoeuvre pressure regulator from fuel rail.
8.Discard 'O' ring.