Vehicles with ES9ZJ4 engine
1. Disconnect the wire terminal «masses» (-) from the negative pole of the battery.
2. Remove the protective cover 1 of the motor (see illustration).
2.2 Remove the protective cover 1 of the motor
3. Remove the air filter and air supply duct 2 (see illustration 2.2).
4. Move away from the place of work the cable 3 of the accelerator drive (see illustration).
2.4 Move away from the place of work the cable 3 of the accelerator drive
5. Disconnect the harness 4 high voltage wires (see illustration 2.4).
6. Disconnect the engine harness 5 together with the holder (see illustration 2.4).
7. Disconnect hose 6 (see illustration 2.4).
8. Disconnect hose 6a, plugs 7, 8, 9,10 and 11, and then hose 12 (see illustration).
2.8 Disconnect hose 6a, plugs 7, 8, 9, 10 and 11 and then hose 12
9. Unscrew bolts 12a (see illustration 2.8). Tightening torque - 15 Nm.
10. Disconnect the cruise control switch box (if provided).
11. Remove the bracket 13 fastening the intake manifold (see illustration).
2.11 Remove the intake manifold mounting bracket 13
12. Unscrew the bolts 14 and remove the intake manifold together with the throttle valve 15 (see illustration 2.11).
13. Plug the inlets with suitable plugs.
Vehicles with ZPJ series engines
14. Disconnect the wire terminal «masses» (-) from the negative pole of the battery.
15. Disconnect plugs and supply air duct 1 from the throttle valve (see illustration).
2.15 Disconnect plugs and supply air duct 1 from the throttle valve
16. Remove the engine protective cover.
17. Disconnect the low pressure hoses from the throttle and idle air control valve (see arrows in illustration).
2.17 Disconnect the low pressure hoses from the throttle and idle air control valve (see arrows)
18. Disconnect the accelerator cable.
19. Unscrew bolt 2 (see illustration 2.17).
20. Disconnect and release from holders on an inlet collector plaits of wires.
21. Disconnect the plugs from the fuel pulsation reduction throttle valve.
22. Unscrew the bolts 3 fastening the intake manifold and remove the manifold (see illustration).
2.22 Unscrew the bolts 3 fastening the intake manifold and remove the manifold