Engine at operating temperature (oil temperature must be at least 80 °C).
Remove
Disconnect wiring harness plug (2) from intake air temperature sensor.
Detach engine vent hose (3) from cylinder head cover.
Detach vacuum line (4) of fuel pressure regulator for air intake pipe from air intake pipe.
Unclip vacuum line (6) from air intake pipe.
Release hose clamps (1) and (5) and detach air intake pipe from throttle body and from upper part of air cleaner housing.
Release wiring harness plug (7) and detach from throttle body.
Remove fastening nut (9) and lay cable bracket with cable (8) aside.
Remove
Remove stud bolts (1), fastening bolts (2) and detach throttle body from intake manifold.
Release wiring harness plug (4) from ignition module control unit and disconnect. Unscrew fastening bolts (arrows) and detach DIS ignition module (3) from spark plugs.
Remove spark plugs with KM-194-E.
Remove
Open relay frame cover.
Remove fuel pump relay and injector relay (1) from socket.
Note. Use compression recorder with rubber cone and measuring range up to 1750 kPa (17.5 bar).
Inspect
Actuate starter for approx. 4 seconds - minimum engine speed 300 rpm. The pressure difference between the individual cylinders should not exceed 100 kPa (1 bar).
Install
Connect fuel pump relay and injector relay into socket - ensure plugged contacts are correct.
Close relay frame cover.
Install spark plugs with KM-194-E - tightening torque 20 Nm / 15 lbf. ft.
Position DIS ignition module on spark plugs and fit to cylinder head cover with fastening bolts.
Tightening torque 9 Nm
Connect wiring harness plug to ignition module control unit and lock.
Note. Before assembling components of the intake system (hoses, connections, etc.), they must be cleaned of any possible contamination (grease, oil, etc.). When tightening the hose clamps, be sure to observe exactly the tightening torque of 3.5 Nm / 2.6 lbf. ft.
Caution
It is only ensured that the intake system is free of leaks, thus ensuring operational safety of the engine, if the hose clamps are tightened correctly to the prescribed tightening torque.
Install
Fit throttle body to intake manifold with new gasket.
Tightening torque 9 Nm
Attach cable retainer to stud bolt - tightening torque 8 Nm / 6 lbf. ft.
Connect wiring harness plug to throttle body and lock.
Attach air intake pipe to throttle body and to upper part of air cleaner housing - secure fastening clamps.
Clip vacuum line into air intake pipe.
Connect hose of fuel pressure regulator for air intake pipe to air intake pipe.
Attach engine vent hose to cylinder head cover.
Connect wiring harness plug to intake air temperature sensor.