CFI unit (1.6 and 1.8 litre (R6A type) CVH) - removal and refitting

Caution: Refer to the precautions in Section 1 before proceeding. A new gasket must be used on refitting.

Removal
1 Disconnect the battery negative lead.

2 Remove the air cleaner assembly.

3 Depressurise the fuel system and disconnect the fuel inlet pipe from the CFI unit.

4 Disconnect the fuel return pipe from the CFI unit. Be prepared for fuel spillage.

5 Disconnect the throttle cable from the linkage on the CFI unit.

6 On 1.6 litre models, either partially drain the cooling system or clamp the coolant hoses as close as possible to the CFI unit to minimise coolant loss, then disconnect the hoses from the unit.

7 Disconnect the wiring plugs for the throttle position sensor, throttle valve control motor, fuel injector and, on 1.6 litre models, the air charge temperature sensor.

8 Disconnect the vacuum pipe from the CFI unit.

9 Unscrew the four (1.6 litre), or three (1.8 litre) securing bolts, and lift the CFI unit from the inlet manifold (see illustration). Recover the gasket.

19.9 CFI unit securing bolts (arrowed) - 1.6 litre CVH
19.9 CFI unit securing bolts (arrowed) - 1.6 litre CVH

Refitting
10 Refitting is a reversal of removal, bearing in mind the following points.

11 Ensure that all mating faces are clean, and use a new gasket.

12 Top-up the cooling system.

13 On completion, turn the ignition on and off five times to pressurise the system, and check for fuel leaks.

Pulse-air filter element (1.6 litre CVH) - renewal

Refer to Chapter 1, Section 37.

Pulse-air system vacuumoperated air valve (1.6 litre CVH) - removal and refitting

1 The valve is mounted at the end of the pulse-air filter housing (see illustration).

21.1 Pulse air system vacuum-operated air valve (arrowed)
21.1 Pulse air system vacuum-operated air valve (arrowed)

2 Disconnect the vacuum hose from the top of the valve, then loosen the hose clips at either end of the valve, and remove the valve.

Note the orientation of the arrow on the valve body, which denotes the direction of flow.

3 Refitting is a reversal of removal, ensuring that the arrow on the valve body is orientated as noted before removal.

Pulse-air delivery tubing (1.6 litre CVH) - removal and refitting

1 Remove the air cleaner assembly.

2 Loosen the hose clips, and disconnect the air hoses from the check valves next to the exhaust manifold (see illustration).

22.2 Pulse-air delivery check valves (arrowed)
22.2 Pulse-air delivery check valves (arrowed)

3 Remove the two bolts securing the check valve bracket to the exhaust manifold.

4 Unscrew the unions securing the air tubes to the manifold, then carefully withdraw the tubing assembly, taking care not to distort the tubes (see illustration).

22.4 Unscrewing a pulse-air delivery tube union
22.4 Unscrewing a pulse-air delivery tube union

5 Refitting is a reversal of removal.

Pulse-air control solenoid (1.6 litre CVH) - removal and refitting

1 The solenoid is located at the right-hand side of the engine compartment.

2 Disconnect the battery negative lead.

3 Disconnect the vacuum pipe connector from the pulse-air control solenoid (see illustration).

23.3 Disconnect the vacuum pipe connector from the solenoid
23.3 Disconnect the vacuum pipe connector from the solenoid

4 Disconnect the solenoid wiring plug, pulling on the plug, not the wiring.

5 Unscrew the securing screw, and withdraw the solenoid from the body panel.

6 Refitting is a reversal of removal, ensuring that the locating lug is correctly positioned, and noting that the vacuum pipes will only fit in one position.

Electronic vacuum regulator (1.8 litre (R6A type) CVH) - removal and refitting

1 The EVR unit is located on the right-hand side of the engine compartment, near the front of the car.

2 Disconnect the battery negative lead.

3 Disconnect the EVR wiring plug, and detach the two vacuum hoses, noting their correct location for refitting.

4 Undo the retaining screws, and remove the EVR unit from the car (see illustration).

24.4 Electronic vacuum regulator retaining screws (arrowed) - 1.8 litre (R6A)
24.4 Electronic vacuum regulator retaining screws (arrowed) - 1.8 litre (R6A) CVH

5 Refitting is a reversal of removal.

Throttle pedal - removal and refitting

Refer to Chapter 4 Part A, Section 11.

Throttle cable - removal, refitting and adjustment

Refer to Chapter 4 Part A, Section 12.

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