1997 FIAT PUNTO Fuel pump relay

2D*10 Engine removal and overhaul procedures
4.36a Relay guard mounting nuts 4.36b Battery tray and mounting bolts 4.36c Disconnect the engine wiring harness located above the transmission .
4.36d ... the inner wiring plug ...
sure that the dnveshaft is positioned to clear Ihe lower suspension arm when the engine is removed. 34 Disconnect the left-hand driveahaft using the same procedure
4.41 Engine wiring harness connections to the battery positive cable
4.36e ... and the outer wiring plug
35 Remove the exhaust front downpipe witfl reference to Chapter 4D. Diesel engines 36 Unbolt and remove the roiay guard then disconnect the wiring as applicable and unbolt the battery tray (see Illustrations). 37 Disconnect tho gear selector cable from the transmission by removing the retaining plate and prising the socket end off Ihe ball on the lever. Use a pair of pliors to pull out the plate. Tie the cable to the bulkhead (see illustration). 38 Unscrew the nut and disconnect the gear selector rod from the ievor on the top of the transmission, 39 Remove the air cleaner and air inlet duct by unscrewing the two bolls securing the duct to the valve cover and loosening the clip securing the duct to the air cleaner. Refer to Chapter 4C if necessary.
4.37 Tie tho gear selector cable to the bulkhead
40 Disconnect the vacuum pipe from the vacuum pump on the left-hand side of the cylinder head and disconnect the wiring plug located over the transmission, 41 Unscrew ihe nuts and disconnect the engine wiring harness from the battery positive cable (see illustration) 42 At the fuel filter unscrew the union bolt and disconnect the fuei delivery hose lor the injection pump. Use polythene and an elastic band to cover the end of the hose (see illustrations). 43 At the fuel injection pump unscrew the clip and disconnect thie fuel return hose (see illustration). 44 Disconnect the radiator top hose from the thermostat housing on tho left-hand side of the cylinder head, and also disconnect the healer hose at Ihe engine (see illustrations). 45 Disconnect the heater return hose and expansion tank hose from the elbow on the
4.42a Unscrew the union bolt and disconnect the fuel delivery hose from the fuel filter 4.42b Cover the end of the hose to prevent dust entry 4.43 Disconnecting the fuel return hose from the fuel injection pump

4A*2 Fuel system - single-point petrol Injection models
1 General information and precautions
General information The iAW Weber-Marelli single point Injection (SPI) system is a self-contained engine management system, which controls both the fuel Injection and Ignition (see Illustration), This Chapter deals with the fuel Injection system components only - refer to Chapter 5B for details ol the ignition system components. The fuel Injection system comprises a fuel tank, an electric fuel pump, a fuel filter, fuel supply and return lines, a throttle body with an integral electronic fuel Injector, and an Electronic Control Unit (ECU) together with its associated sensors, actuators and wiring. The fuel pump delivers a constant supply of fuel through a cartridge fitter to the throttle body, and the fuel pressure regulator (integral with the throttle body) maintains a constant fuel pressure at the fuel injector and returns excess fuel to the tank via the return line. This
constant flow system also helps to reduce fuel temperature and prevents vaporisation. Tne fuel injeclor Is opened and closed by an Electronic Control Unit (ECU), which calculates the injection timing and duration according to engine speed, throttle position and rate of opening, Inlet air temperature, coolant temperature and exhaust gas oxygen content information, received from sensors mounted on the engine. inlet air is drawn Into the engine through the air cleaner, which contains a renewable paper filter element. The inlet air temperature is regulated by a vacuum operated valve mounted in the air ducting, which blends air at ambient temperature with hot air, drawn from over the exhaust manifold. Idle speed is controlled by a stepper motor located on the side of the throttle body. Cold starling enrichment is controlled by the ECU using the coolant temperature and inlet air temperature parameters to increase the injector opening duration. The exhaust gas oxygen content is constantly monitored by the ECU via the Lambda (oxygen) sensor, which is mounted in
me exhaust downpipe. The ECU then uses this Information to modify the Injection timing and duration to maintain the optimum air/fuel ratio. An exhaust catalyst Is fitted to all SPI models. The ECU also controls the operation of the activated charcoal filter evaporative loss system • refer to Chapter 4D for further details. It should be noted that fault diagnosis of the I IAW Weber-Marelli system is only possible with dedicated electronic test equipment. Problems with the system should therefore be I referred to a Flat dealer for assessment. Once i the fault has been Identified, the I removal/refitting procedures detailed in the following Sections can then be followed.
Precautions |

A


Warning: Many procedures in thH Chapter require the removal ot fuel lines and connections, which may result in fuel spillage. Before carrying | out any operation on Me fuel system, refer to the precautions given In Safety flrstt at the beginning ot this manual, and follow them Implicitly. Petrol Is a highly dangerous and volatile liquid, and the precautions
1.1 IAW Weber-Marelli single point Injection (SPI) system 1 Fuel
tank
2 Fuel pump 3 Fuel filter 4 Anii'reflux valve 5 Fuel pressure regulator 6 Injector
7 Air cleaner 8 Fuel vapour
trap
9 Idle stepper motor
10
Absolute pressure sensor J11njection/ignition ECU 12 Tnrottle position sensor
13 Engine coolant temperature sensor 14 Intake air temperature sensor 15 Inject'onfignitron dual
relay
16 Ignition coils 17 Rpm and TDC sensor
18 Spark plugs 79 Diagnostic socket 20 EVAP solenoid 21 Lambda/oxygen sensor 22 Rev counter 23 IAW failure warning light

Ihe right-hand front roadwheel and the protective plastic cover under the wheelarch. 37 Disconnect the sensor wiring plug on the front of the engine. 38 Detach the sensor from its mounting. Refitting 39 After refitting Ihe sensor use a feeler blade to check that the gap between sensor and the serrated part of the crankshaft pulley Is between 0.5 and 1.S mm. No adjustment is possible and if the gap is incorrect the sensor and pulley should be checked for possible damage.
Electronic control unit (ECU)
Removal Note: 77ie engine management system has a (earning capability which allows the ECU to store details of the engine's running
characteristics
in its memory,
This
memory
will
tie erased by the disconnection of the battery
cables,
with the resuit that the engine may idle
roughly,
or lack performance for a while, until
the
engine's characteristics are re-teamt. 40 The ECU {electronic control unit) is located on the right-hand Inner wing (see illustration). The 3-pin socket by the ECU is for connection of diagnostic test equipment. 41 Disconnect the battery negative terminal (refer to D/sconnecffng the battery in the Reference Section of this manual). 42 Disconnect the ECU wiring connector, then undo the retaining nuts and remove the unit from the bracket In the engine compartment. Refitting 43 Refitting Is a reversal of removal making sure that the wiring connector is securely reconnected. Inertia safety switch
Removal 44 The inertia safety switch is located by the left-hand side passenger seat. First pull back
the
carpet for access. 45 Disconnect the wiring then unbolt the switch. Refitting 48 Refitting is a reversal of removal.
Fuel injection system relays
Removal 47 The fuel injection system relay is located under a plastic cover on the bulkhead. The MAP sensor is also located under the same cover. 48 Two separate relays are incorporated in the single housing; the left-hand relay has a 5 amp fuse and the right-hand relay has a 25 amp fuse. The main purpose of the relays is to supply current to the fuel pump, ignition coils, oxygen sensor. Injectors and EVAP solenoid. The main relay is controlled by the ignition switch.
4A*2 Fuel system - single-point petrol Injection models
6 Fuel pump/fuel gauge sender unit -removal and refitting
Removal Note: Refer to the warning given in Section 1 before proceeding. 1 Disconnect the battery negative terminal (refer to Disconnecting the battery in the Reference Section of this manual). 2 Remove the rear seat as described in Chapter 11. Prise the fuel pump access cover out of the floor panel to gain access to the pump unit. 3 Disconnect the wiring connector. 4 Bearing in mind the warning given in Section t, disconnect the fuel supply and return lines from the pump unit by pressing the tabs (see illustration). Plug the ends of the lines or cover them with adhesive tape. 5 Using a suitable toot, unscrew the large ring nut and carefully withdraw the fuel pump/fuel tank sender unit assembly from the fuel tank, along with its sealing ring. 6 If necessary, the unit can be dismantled and the pump and sender unit separated. If this is the case, carefully note the correct
fitted positions of oil components while dismantling the unit, and use these notes on reassembly to ensure that all items are correctly fitted.
Refitting 7 Refitting is a reversal of the removal procedure using a new sealing ring. Prior to refitting the access cover, reconnect the battery, then start the engine and check the feed and return unions for signs of leakage.
5.40 ECU located on the right-hand inner wing 49 Remove the cover and pull the relay directly from its socket. Refitting 50 Refitting Is a reversal of removal.
7 Fuel tank -removal and refitting
6.4 Press the tabs Indicated to disconnect the fuel supply and return tines
Note: Refer to the warning given in Section 1 before proceeding.
Removal 1 Before removing the fuel tank, all fuel must be drained from the tank. Since a fuel tank drain plug is not provided, it is therefore preferable to carry out the removal operation when the tank is nearly empty. Before proceeding, disconnect the battery negative terminal (refer to Disconnecting the battery In the Reference Section of this manual), and syphon or hand-pump the remaining fuel from the tank. 2 Remove the fuel pump/fuel gauge sender unit as described in Section 6. 3 Chock the front wheels, then jack up the rear of the vehicle and support on axle stands (see Jacking and vehicle support). 4 Loosen the clip and disconnect the filler pipe from the nght-hand side of the fuel tank. 5 Undo the tank flange and strap mounting bolts, then lower the tank out of position until It is possible to access the hose connections on top of the tank. 6 Loosen the clips and disconnect the EVAP purge hose and breather hose from the fuel tank. If necessary, the filler neck can be detached from the body. 7 Check that all hoses and wiring is disconnected, then remove the tank from underneath the vehicle. Refitting 8 Refitting is a reversal of the removal procedure, ensuring all hoses are correctly routed and securely reconnected.
8 Fuel injection system - ^ depressurisation
Note: Refer to the warning given In Section t before proceeding.

A


Warning; The following procedure will merely relievo the pressure in the fuel system • remember that fuel will still be present In the system components and take precautions accor-dingly before disconnecting any of them.

4A*2 Fuel system -
single-point
petrol Injection models
1 General information and precautions
General information The
LAW
Weber-Maretil multi-point Injection (MPI) system is a self-contained engine management system, which controls both the fuel injoction and Ignition (see Illustrations). This Chapter deals with the fuel Injection system components only - refer to Chapter 5B for details of the ignition system components. The fuel injection system comprises a fuel tank, an electric fuel pump, a fuel filter, fuel supply end return lines, a throttle body, a fuel rail with four electronic Injectors, and an Electronic Control Unit (ECU) together with its associated sensors, actuators and wiring. On pre-1998, 8-valve engines and all 16-valve engines, the fuel pump delivers a constant supply of fuel through a cartridge filter to the fuel rail, and the fuel pressure regulator (located on Ihe fuel rail) maintains a constant fuel pressure at the fuel Injectors and returns excess fuel to the tank via the return
line, This constant flow system also helps to reduce fuel temperature and prevents vaporisation. On later 8-valve engines, a returnless fuel system is used. With this arrangement, the fuel filter and fuel pressure regulator are an integral part of the fuel pump assembly located In the fuel tank. The regulator maintains a constant fuel pressure in the supply line lo the fuel rail and allows excess fuel to recirculate in the fuel tank, by means of a bypass channel, if the regulated fuel pressure is exceeded. As the fuel filler Is an integral part of the pump assembly, fuel filter renewal Is no longer necessary as part of the maintenance and servicing schedule. The fuel injectors are opened and closed by an Electronic Control Unit (ECU), which calculates the Injection timing and duration according to engine speed, throttle position and rate of opening, inlet air temperature, coolant temperature and exhaust gas oxygen content information, received from sensors mounted on the engine. The injectors are operated simultaneously (le not sequentially) and Inject half of the quantity of fuel required on each turn of the crankshaft. Inlet air Is drawn into the engine through
the air cleaner, which contains a renewable paper filter element. On 8-valve engines, the Inlet air temperature is regulated by a vacuum operated valve mounted in the air ducting, which blends air at ambient temperature with hot air, drawn Irom over the exhaust | manifold. Idle speed Is controlled by a stepper motor 1 located on the side of the throttle body. Cold storting enrichment is controlled by the ECU using the coolant temperature and Inlet air temperature parameters to Increase the Injector opening duration. The exhaust gas oxygen content it constantly monitored by the ECU via the Lambda/oxygen sensor, whioh Is mounted in the exhaust downpipe. The ECU then uses this Information to modify the Injection timing and duration to maintain the optimum air/fuel ratio. An exhaust catalyst is fitted to all models. The ECU also controls the operation of the activated charcoal filler evaporative loss system - refer to Chapter 4D for further details. It should be noted that fault diagnosis of the IAW Weber-Marelll system Is only possible with dedicated electronic test equipment.
1.1a IAW Weber-Marelii multt-point Injection (MPi) system (8-valve engines) f Fuel
tank
7 Air
cleaner
13 Coolant temperature sensor 19 Diagnostic socket 2 Fuel pump 8 Fuel vapour trvp 14 Intake air temperature 20
EVAP
solenoid 3 Filter (pre-1998 models) 9 Idle control stepper motor sensor 21 Lambda/oxygen sensor 4 Fuel
rail
10 Manifold absolute pressure 15 Duel
relay
22 Rev counter 5 Pressure regulator
(pre-1998
sensor 16 Ignition colls 23 IAW failure warning light models)
11 ECU
17 Rpm and TDC sensor 24 Anti-refhjx
valve
6 Injectors 12 Throttle position sensor 18 Spark piugs

4A*2 Fuel system -
single-point
petrol Injection models
1.1b IAW Weber-Marelli multi-point injection (MPI) system (16-valve engines) J Fuel
tank
2 Fuel pump 3 Multi-purpose
valve
4 Safety
valve
5 Anti-reflux
valve
6 F/fter 7 Battery 8
EVAP
solenoid
9 Dual
relay
10 Ignition switch 111nertia switch
12
Air conditioning compressor
13
Fuse 14 Throttle position sensor

1$
idle control stepper motor 17 Ignition coils 18 Sparkplugs 19 Fuel
rail
20 Pressure regulator 21 Injectors
15
Intake air temperature/pressure 22 Coolant temperature sensor sensor 23 Lambda/oxygen sensor
24 Rpm and TDC sensor 25 Engine immobiliser control unit 26 Catalytic converter 27 IAW failure warning light 28 EVAP canister 29 ECU 30 Diagnostic socket 31 Rev counter
Problems with the system should therefore be referred to a Fiat dealer for assessment. Once the fault has been Identified, the removal/ refitting procedures detailed in the following Sections can then be followed.
Precautions

A


Warning: Many procedures In this Chapter require the removal of fuel lines and connections, which may result In fuel spillage. Before carrying out any operation on the fuel system, refer to the precautions given In Safety flrstl at the beginning of this manual, and follow them implicitly. Petrol Is a highly dangerous and volatile liquid, and the precautions necessary when handling it cannot be overstressed. Note that residual pressure will remain in the fuel lines long after the vehicle was last used, When disconnecting tny fuel line, first depressurise the fuel system {see Section 9).
2 Air cleaner and inlet system Sk - removal
and
refitting ^
Removal
1242 cc (8-valve) engines 1 Remove the air cleaner element as described In Chapter 1A. 2 Disconnect the outer section from the hot air tube and the Inlet air duct and remove it from the engine compartment. 3 If necessary remove the inlet air duct. 4 Disconnect the large and small breather hoses from the inner section of the air cleaner, then unscrew the retaining nuts and lift the section from the throttle body. 5 Recover the sealing ring. Check the nng for condition and renew it it necessary. 6 Wipe clean the inner surfaces of both the Inner and outer sections of the air cleaner,
1242 cc (16-valve) engines 7 Release the hose clip and disconnect the inlet air duct from the resonator (see illustration).
2.7 Release the hose clip and disconnect the inlet air duct from the resonator

4A*2 Fuel system -
single-point
petrol Injection models
b) Ensure that the injector retaining clips are securely seated c) Make sure the fuel supply and return hoses are correctly fitted as noted on removal, d) Check that all vacuum and electrical connections are remade
correcily
and securely. e) On completion check the fuel rail and injectors for fuel leaks.
Fuel pressure regulator Note: On J998 models onward, the fuel pressure regulator is an integral pad of the fuel pump and cannot be renewed separately. The following procedure applies to pre-1998 models only. Removal 17 Remove the air cleaner and inlet air ducts as described In Section 2. 18 Oepressurise the fuel system as described in Section 9. 19 Disconnect the vacuum hose from the port on the side of the regulator. 20 Extract the retaining clip and pull the pressure regulator out of Ihe fuel rail. 21 Remove the O-ring seal. Refitting 22 Refit the fuel pressure regulator by following Ihe removal procedure in reverse, noting the following points: a) Renew the O'ting seal and smear it with a little Vaseline before assembling. b) When fitting the retaining clip, use a suitable socket or metal tube (o press In the three anchorage points at Ihe same time. c) Refit the vacuum hose securely.
Idle control stepper motor
23 Refer to Chapter 4A.
Throttle potentiometer 24 Refer to Chapter 4A,
Intake air temperature sensor 25 Refer to Chapter 4A.
Manifold absolute pressure (MAP) sensor 26 Reler to Chapter 4A.
6.12a Disconnect the wiring connectors for the fuel injector harness ...
6.3 Disconnect the wiring connectors from the throttle potentiometer and the idle control stepper motor
Coolant temperature sensor 27 Refer to Chapter 4A. Crankshaft TDC sensor 28 Refer to Chapter 4A. Electronic control unit (ECU)
29 Refer to Chopter 4A.
Inertia safety switch 30 Refer to Chapter 4A. Fuel injection system relays 31 Refer to Chapter 4A.
6 Engine management system ^ components
(1242
cc,16-vatve S engines) - removal and refitting ^
Note: Refer to the warning given in Section t before proceeding.
Throttle body assembly
Removal 1 Remove the resonator, air cleaner and inlet air duct as described in Section 2. 2 Free Ihe accelerator inner cab 6.12b ... and intake air temperature/pressure sensor
4 Slacken and remove the three bob j securing the throttle body assembly to ite inlet manifold. Ihen remove the assent?/ along with its insulating spacer. As the
throaii 1-
body is withdrawn, disconnect the vacuum hose from the underside of the unit. Refitting 5 Refitting is a reversal of the removal pi>: cedure, bearing in mind the following pants a) Examine the insulating spacer for signs d damage, and renew if necessary. b) Ensure the throttle body, inlet
manddd
and insulating spacer mating surfaces at -clean and dry. then fit the throttle
btxty
and spacer, and securely tighten the retaining bolts. c) Adjust Ute accelerator cable as desciter /nSecfw?4.
Fuel rail and injectors
Removal 6 Disconnect the battery negative termrul; (refer to Disconnecting the battery in ir*J Reference Section ol this manual), 7 Remove the resonator, air cleaner arid io«l 1 air duct as descnbed in Section 2. 8 Free the accelerator Inner cablc from l>*
1
throttle cam, remove the outer cable sprig. clip, then pull the outer cable out from
>H
mounting bracket rubber grommet, 9 From the side of the throttle bod/, | disconnect the wiring connectors from Ihs: throttle potentiometer and the idle cofttro^ stepper motor. 10 Oepressunse the fuel system si ' described in Section 9. ' 11 Loosen the clips or release tho quick-. release couplings and disconnect the fuel MdJ' and outlet hoses from the left-hand end oftfu fuel rail, below the throttle body. Note IM fitted positions ol the hoses to aid relirtirf i later. Undo the support bracket retaining bol and move the fuel hoses to one side. 12 Disconnect Ihe wiring connectors forth* fuel injector harness and the Intake an temperature/pressure sensor (m illustrations). 13 Disconnect the fuel pressure regulator-! vacuum hose and the EVAP purgo vaive h«* (see illustrations).
6.13a Disconnect the fuel pressure regulator vacuum hose...

4A*2 Fuel system -
single-point
petrol Injection models
Refitting 37 Refitting Is a reversal of removal making sure that the wiring connector is securely reconnected.
Inertia safety switch 36 Refer to Chapter 4A, Fuel injection system relays Removal 39 The fuel injection system twin relay Is located under a plastic cover on the engine compartment bulkhead. 40 The main purpose of the relay Is to supply current to the fuel pump, ignition coils, oxygen sensor, Injectors and EVAP solenoid. The relay is controlled by the ignition switch. A15 amp fuse, protecting ihe fuel pump, oxygen sensor and EVAP solenoid is located adjacent to the relay. 41 Remove the cover and pull the relay directfy from Its socket. Refitting 42 Refitting is a reversal of removal.
7 Fuel pump and fuel gauge sender unit - JK removal
and
refitting ^
Removal Note: Refer fo (he warning given in Section 1 before proceeding. 1 Disconnect the battery negative terminal (refer to Disconnecting the battery In the Reference Section of this manual). 2 Depreasurise the fuel system as described in Section 9. 3 Remove the rear soat as described In Chapter 11. Prise the fuel pump access cover out of the floor panel to gain access to the pump unit. On later models, undo the three retaining screws to release the cover. 4 Disconnect the wiring connector. 5 Bearing In mind the warning given In Section t, disconnect Ihe fuel supply and, where applicable, the return lines from tho pump unit by pressing the tabs. Plug the ends of the lines or cover them with adhesive tape. 6 Using a suitable tool, unscrew the large ring nut and carefully withdraw the fuel pump/fuel tank sender unit assembly from the fuel tank, along with its sealing rtng. 7 If necessary, the unit can be dismantled and the pump and sender unit separated. If this is (he case, carefully note the correct fitted positions of all components while dismantling the unit, and use these notes on reassembly to ensure that all items are correctly fitted.
Refitting 8 Refitting is a reversal of the removal procedure using a new sealing ring. Prior to refitting the access cover, reconnect the battery, then start the engine and check the fuel line unlon(s) (or signs of i

Fuel
tank -removal and refitting
Refer to Chapter 4A.
9 Fuel injection system -depressurisatton
Note: Refer to the warning given In Section 1 before proceeding.

A


Warning: The following procedure will merely relieve the pressure In the fuel system • remember that fuel will still be present In the system components and take precautions accord-ingly before disconnecting any of them. 1 The fuel system referred to in this Section is defined as the lank-mounted fuel pump, tha fuel filter, the fuel rail, the fuel injectors, and the metal pipes and flexible hoses of the fuel lines between these components. All these contain fuel which will be under pressure while the engine Is running and/or while the Ignition is switched on. The pressure will remain for some time after the Ignition has been switched off. and must be relieved before any of these components are disturbed for servicing work. 2 Disconnect the battery negative terminal (refer to Disconnecting the battery In the Reference Section of this manual). 3 Have a large rag ready to cover the union to be disconnected and, if possible, place a con-tainer beneath the relevant connection/union. 4 Slowly loosen the connection or union nut (as applicable) to avoid a sudden release of pressure, and ensure that the rag is wrapped around the connection to catch any fuef spray which may be expelled. Once the pressure is released, disconnect the fuel line, and Insert plugs to minimise fuel loss and prevent the entry of dirt Into the fuel system. Note that on later models, quick-release fuel couplings are used on many of the fuel line connections. To release these couplings, depress the two clips on the side of the coupling while keeping the fuel line pushed In. With the clips depressed, slowly withdraw the fuel line from the coupling allowing the fuel pressure to release, then withdraw the fuel line fully.
10 Inlet manifold-removal
and
refitting
Note: Refer fo the warning given in Section 1 before proceeding.
1242 cc (8-valve) engines
Removal 1 Remove ihe throttle body assembly as described in Section 5.
2 Remove the fuel rail and injectors at described in Section 5. 3 Drain the cooling system ss described n Chapter 1A. 4 Disconnect the wiring connector from ih* coolant temperature sensor (situated on it* left-hand side of the manifold). 5 Undo the bolt securing the accelerator cable mounting bracket to the manifold, am position it clear of the manifold. 6 Slacken the retaining clip and disconnect the coolant hose from the rear of the mandold 7 Disconnect the brake vacuum hose, 6 Undo the seven manifold retaining nuisw bolts, and remove the manifold from tta engine. Remove the gasket and discard tti new one should be used on refitting. Refitting
9 Refitting is a reverse of the removjf procedure, noting the following points: a) Ensure that the manifold and cylinder lim mating surfaces are dean and
dry.
and fill new manifold gasket. Refit the
manifold
and securely tighten Its retaining
nuts.
b) Ensure all relevant hoses are recorwscfed fo their original positions and are
sacurtfy
held (Where necessary; by the
retaining
clips. c) Refit the fuel rail and injectors, and
the
throttle body assembly with
reference to
Sect/on 5. d) On completion, refill the cooling
system
as described in Chapter 1A. 1242 cc (16-valve) engines
Removal 10 Disconnect the battery negative ternnncf (refer to Disconnecting the battery in ths Reference Section of this manual). 11 Remove the resonator, air cleaner and inlet air duct as described In Section 2. 12 Drain the cooling system as described r, Chapter 1A. 13 Free the accelerator inner cable from IN throttle cam. remove the outer cable spring dip. then pull the outer cable out from itt mounting bracket rubber grommet. 14 From the side of the throttle boOf, disconnect the wiring connectors from the throttle potentiometer and the Idle contrd stepper motor. Disconnect the coolant temperature sensor wiring connector located in the Inlet manilold below the throttie bodr, and disconnect the brake servo vacuum hose. 15 Disconnect Ihe wiring connectors for the fuel in|ector harness and the Intake a* temperature/pressure sensor, thtn disconnect the fuel pressure regulator vacuum hose and the EVAP purge valve
hose
(see illustration). 16 Undo Ihe two bolts securing the plastic Inlet manifold upper section to the lower section. Release the spark plug HT lead from the location groove in the manifold upper section, then lift Ihe upper section, complete with throttle body, off the engine. Recover
the
O-rings from the manifold pons.

Fuel system - diesel models
4C*3

9.9 Removing the fire seal washor 9.13 Tightening an injector with a torque wrench
Refitting 10 Obtain new fire seal washers. 11 Take care not to drop the Injectors, or tfow the needles at their tips to become damaged. The injectors are prectsion-mado to Ine knits, and must not be handled roughly. In particular, never mount them in a bench vice. 12 Commence refitting by inserting the fire
seal
washers {convex face uppermost}. 13 Insert the injectors and tighten them to the specified torque (see illustration). 14 Refit the injector pipes and tighten the union nuts. Make sure the pipe clamps are in Iteir previously-noted positions. If the clamps
are
wrongly positioned or missing, problems may be expenenced with pipes breaking or splitting,
15 Reconnect the leak-off pipes. 16 Refit the air ducting. 17 Start the engine, and check for any leakage at the fuel unions. To enable the engine to start it may be necessary to loosen the Injector union nuts while turning the engine on the starter motor in order to purge trapped air.
10 Fuel gauge sender unit -removal and refitting
Refer to Chapter 4A, hov/ever note that the unit does not Incorporate a pump (see illustrations).
11 Fuel tank -removal and refitting
Refer to Chapter 4A, however note that in addition a safety valve with an anti-roll device is fitted in the top of the tank with a ventilation pipe to the front of the tank. The fuel gauge sender unit does not Incorporate a pump as this unit is located In the injection pump.
12 Inlet manifold - ^ removal and refitting %
Note: The Inlet and exhaust manifolds are both located on the rear of the engine and share the same securing bolts and gasket. Although the following procedure describes removal of the Inlet manifold separately it may be necessary to remove the exhaust manifold as well In order to renew the gasket.
Removal 1 Remove the air cleaner and ducting as described in Section 2. 2 Unbolt and remove the relay guard and bracket from the left-hand side of the engine. 3 On turbo models disconnect the air duct from the inlet manifold elbow. If necessary the elbow can be unbolted from the manifold and the sealing ring removed. 4 Unscrew the nuts securing the inlet manifold to the cylinder head noting the position of the support bracket. Note lhat some of the nuts also secure the exhaust manifold. Withdraw the inlet manifold from the studs (see illustrations), 5 Examine the gasket. If It is damaged it will be necessary to remove the exhaust manifold in order to renew it.
Refitting 6 Refitting Is a reversal of removal, but tighten all nuts and bolts lo the specified torque.
12.4c Removing the Inlet manifold