Peugeot 205 (954 cc, 1124 cc, 1360 cc, 1580 cc & 1905 cc). Manual - part 15

Throttle damper

53 Refer to the procedures contained in
paragraphs 29 and 30 

Additional adjustments

54 At the time of writing, not further
information was available relating to any
further adjustment of these carburettors.

11 Inlet manifold - removal and

refitting

3

Removal

1 Disconnect the battery negative lead.
2 Drain the cooling system as described in
Chapter 1.

3 Remove the air cleaner assembly and
carburettor(s) as described in Sections 2 and 9.
4 Where applicable, disconnect the brake
servo vacuum hose from the manifold (see
illustration).
5 Disconnect the coolant hoses from the
manifold together with any cable clips and
support brackets.
6 Unbolt the manifold, releasing any
additional attachments as necessary and
remove it from the cylinder head (see
illustration). Where fitted, recover the gasket
or seals.

Refitting

7 Refitting is a reversal of removal, bearing in
mind the following points:

a) Ensure that the manifold and cylinder

head mating faces are perfectly clean and

use a new gasket or seals on models so
equipped. On TU engines apply a thin
coating of suitable sealing compound to
the manifold mating face before fitting -
no gasket is used on these engines.

b) Ensure that all hoses are reconnected to

their original positions and are securely
held by their retaining clips.

c) Refit the carburettor(s) and air cleaner

assembly as described in Sections 9
and 2.

d) On completion, refill the cooling system

as described in Chapter 1.

4A•10 Fuel system - carburettor engines

11.4  Disconnecting the brake servo vacuum hose at the inlet

manifold - TU series engine shown

11.6  Unscrewing the inlet manifold retaining nuts - 

TU series engine shown

4B

Chapter 4  Part B:
Fuel system - single-point fuel injection engines

General

System type  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear-mounted fuel tank, electric fuel pump, single-point fuel injection
system

System application:

TU1M/Z, TU3M/Z and TU3FM/L engines.  . . . . . . . . . . . . . . . . . . . . .

Bosch Mono-Jetronic A2.2

XU5M2/Z engines  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MMFD Mono-point G5

TU1M/L, XU5M3/Z and XU5M3/L engines  . . . . . . . . . . . . . . . . . . . . .

MMFD Mono-point G6

Fuel system data

Idling speed*  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

850 ± 50 rpm

Idle mixture CO content*  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Less than 1.0 %

*Not adjustable, controlled by ECU - data given for reference purposes only

Recommended fuel

Minimum octane rating (see text Section 8)  . . . . . . . . . . . . . . . . . . . . . .

95 RON unleaded. Leaded fuel must not be used

Air cleaner assembly - removal and refitting  . . . . . . . . . . . . . . . . . . . 2
Air cleaner element renewal  . . . . . . . . . . . . . . . . . . . . . .See Chapter 1
Fuel filter renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .See Chapter 1
Fuel gauge sender unit - removal and refitting  . . . . . . . . . . . . . . . . . 6
Fuel injection system - testing and adjustment  . . . . . . . . . . . . . . . . . 10
Fuel injection systems - general information  . . . . . . . . . . . . . . . . . . . 9
Fuel pump - removal and refitting  . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Fuel system - depressurisation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Fuel tank - removal and refitting  . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
General fuel system checks  . . . . . . . . . . . . . . . . . . . . . .See Chapter 1

General information and precautions  . . . . . . . . . . . . . . . . . . . . . . . . 1
Inlet manifold - removal and refitting  . . . . . . . . . . . . . . . . . . . . . . . . . 13
MMFD Mono-point G5 and G6 system components - removal   . . . .

and refitting  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Mono-Jetronic A2.2 system components - removal and refitting  . . . 11
Throttle cable - removal, refitting and adjustment . . . . . . . . . . . . . . . 3
Underbody and fuel/brake line check  . . . . . . . . . . . . . . .See Chapter 1
Underbonnet check for fluid leaks and hose condition . .See Chapter 1
Unleaded petrol - general information and usage  . . . . . . . . . . . . . . . 8

4B•1

Specifications

Contents

Easy, suitable for
novice with little
experience

Fairly easy, suitable
for beginner with
some experience

Fairly difficult,
suitable for competent
DIY mechanic

Difficult, suitable for
experienced  DIY
mechanic

Very difficult,
suitable for expert DIY
or  professional

Degrees of difficulty

5

4

3

2

1

1

General information and
precautions

General information

The fuel system consists of a fuel tank

(which is mounted under the rear of the car,
with an electric fuel pump immersed in it), a
fuel filter, fuel feed and return lines, and the
throttle body assembly (which incorporates
the single fuel injector and the fuel pressure
regulator). In addition, there is an Electronic
Control Unit (ECU) and various sensors,
electrical components and related wiring. The
air cleaner contains a disposable paper filter
element, and incorporates a flap valve air
temperature control system. This allows cold
air from the outside of the car and warm air
from around the exhaust manifold to enter the
air cleaner in the correct proportions.

Refer to Section 9 for further information on

the operation of each fuel injection system.

Precautions

Warning: Petrol is extremely
flammable - great care must be
taken when working on any part
of the fuel system. Do not smoke

or allow any naked flames or uncovered
light bulbs near the work area. Note that
gas powered domestic appliances with pilot
flames, such as heaters, boilers and tumble
dryers, also present a fire hazard - bear this
in mind if you are working in an area where
such appliances are present. Always keep a
suitable fire extinguisher close to the work
area and familiarise yourself with its
operation before starting work. Wear eye
protection when working on fuel systems
and wash off any fuel spilt on bare skin
immediately with soap and water. Note that
fuel vapour is just as dangerous as liquid
fuel; a vessel that has just been emptied of

liquid fuel will still contain vapour and can
be potentially explosive. Petrol is a highly
dangerous and volatile liquid, and the
precautions necessary when handling it
cannot be overstressed.

Many of the operations described in this

Chapter involve the disconnection of fuel
lines, which may cause an amount of fuel
spillage. Before commencing work, refer to
the above Warning and the information in
“Safety first” at the beginning of this
manual.

When working with fuel system

components, pay particular attention to
cleanliness - dirt entering the fuel system
may cause blockages which will lead to
poor running.

Note: Residual pressure will remain in the

fuel lines long after the vehicle was last used.
When disconnecting any fuel line, first
depressurise the fuel system as described in
Section 4.

2

Air cleaner assembly -
removal and refitting

1

Refer to the procedures in Chapter 4A,

Section 2, substituting “throttle body” for all
references to the carburettor.

3

Throttle cable - removal,
refitting and adjustment

2

Removal and refitting

1 Refer to Chapter 4A, Section 3 substituting
“throttle body” for all references to the
carburettor. Adjust the cable as described
below.

Adjustment

2 Remove the spring clip from the adjustment
ferrule then, ensuring that the throttle cam is
fully against its stop, gently pull the cable out
of its grommet until all free play is removed
from the inner cable.
3 With the cable held in this position, ensure
that the flat washer is pressed securely
against the grommet, then fit the spring clip to
the third ferrule groove visible in front of the
rubber grommet and washer (see
illustration). This will leave a fair amount of
freeplay in the inner cable which is necessary
to ensure correct operation of the idle speed
control motor.
4 Have an assistant depress the accelerator
pedal and check that the throttle cam opens
fully and returns smoothly to its stop.

4

Fuel system -
depressurisation

1

Note: Refer to the warning note in Section 1
before proceeding.

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 accordingly before
disconnecting any of them.
1 The fuel system referred to in this Section is
defined as the tank-mounted fuel pump, the
fuel filter, the fuel injector and the pressure
regulator in the injector housing, 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 it must be relieved in a
controlled fashion when any of these
components are disturbed for servicing work.
2 Disconnect the battery negative lead.

3 If possible, place a suitable container
beneath the connection or union to be
disconnected, and have a large rag ready to
soak up any escaping fuel not being caught
by the container.
4 Slowly loosen the connection or union nut to
avoid a sudden release of pressure, and
position the rag around the connection, to catch
any fuel spray which may be expelled. Once the
pressure is released, disconnect the fuel line.
Plug the pipe ends, to minimise fuel loss and
prevent the entry of dirt into the fuel system.

5

Fuel pump - removal and
refitting

3

Note: Observe the precautions in Section 1
before working on any component in the fuel
system.

Removal

1 Disconnect the battery negative lead.
2 Raise the rear seat cushion.
3 Prise up the right-hand plastic cover from
the floor then disconnect the wiring, and the
fuel supply and return pipes, noting their
location (see illustration).
4 Unscrew the retaining screws and lift the
fuel pump housing from the fuel tank. Note
that in some cases, the hole in the floor may
not be aligned with the pump, in which case
the fuel tank may need to be lowered for
access (refer to Section 7 for details).
5 Release the filter from the bottom of the
housing, then the collar (see illustration).

6 Disconnect the wiring and release the fuel
pump from the upper collar.

Refitting

7 Refitting is a reversal of removal, but fit new
collars and make sure that the wiring
terminals are positioned away from the pump
terminals. Always fit a new gasket between
the pump housing and fuel tank.

6

Fuel gauge sender unit -
removal and refitting

3

Refer to Part A, Section 6.

7

Fuel tank - removal and
refitting

3

Refer to Part A, Section 7, noting that it will

be necessary to depressurise the fuel system
as the feed and return hoses are
disconnected from the fuel pump (see Section
5). It will also be necessary to disconnect the
wiring connector from the fuel pump before
lowering the tank out of position.

4B•2 Fuel system - single-point fuel injection engines

3.3  Adjust the throttle cable as described

in text

5.3  Fuel pump locations and connections

5.5  Fuel pump components

1

Bleed tube

2

Bracket

3

Collar

4

Collar

5

Fuel pump

6

Filter

8

Unleaded petrol - general
information and usage

Note: The information given in this Chapter is
correct at the time of writing. If updated
information is thought to be required, check
with a Peugeot dealer. If travelling abroad,
consult one of the motoring organisations (or a
similar authority) for advice on the fuel
available.

All Peugeot 205 single-point fuel injection

models are designed to run on fuel with a
minimum octane rating of 95 (RON). All
models are equipped with catalytic
converters, and therefore must be run on
unleaded fuel only. Under no circumstances
should leaded fuel be used, as this may
damage the catalytic converter.

Super unleaded petrol (97/98 RON) can

also be used in all models if wished, though
there is no advantage in doing so.

9

Fuel injection systems -
general information

Bosch Mono-Jetronic A2.2
system

The Mono-Jetronic A2.2 system is a

single-point fuel injection system
incorporating a catalytic converter in the
exhaust system.

The fuel pump, located in the fuel tank,

pumps the fuel through a filter to the single
fuel injector. The electronic control unit (ECU),
which is triggered by the ignition circuit, sends
impulses to the injector, which sprays fuel
upstream of the throttle valve. A constant fuel
pressure is maintained by a fuel pressure
regulator, which returns excess fuel to the fuel
tank. The ECU also receives information from
various sensors to determine engine
temperature, speed and load, and the quality
of air entering the engine. The sensors inform
the ECU of throttle position, inlet air
temperature, coolant temperature, and
exhaust gas oxygen content. Engine speed
and crankshaft position information is
provided by the ignition circuit. All the
information supplied to the ECU is computed
and compared with pre-set values stored in
the ECU memory, to determine the required
period of injection. The injector operates four
times per engine cycle, and the injector
opening duration is varied to control the
quantity of fuel delivered.

The ECU constantly varies the fuel mixture

and engine idle speed to provide optimum
engine efficiency under all operating
conditions, and to reduce exhaust gas
emissions. The mixture strength is accurately
controlled to maintain it within the operating
limits of the catalytic converter.

MMFD Mono-point G5 and G6
systems

The Mono-point G5 and G6 systems are

single-point fuel injection systems also
incorporating a catalytic converter in the
exhaust system. The only difference between
the two systems is that the idle speed is
controlled via a control valve on the G5
system, and via a control motor on the G6
system. The system operation is as described
above for the Mono-Jetronic system and is
under the overall control of an electronic
control until (ECU), which also controls the
ignition system.

10 Fuel injection system -

testing and adjustment

3

Testing

1 If a fault appears in the fuel injection
system, first ensure that all the system wiring
connectors are securely connected and free
of corrosion. Ensure that the fault is not due to
poor maintenance; ie, check that the air
cleaner filter element is clean, the spark plugs
are in good condition and correctly gapped,
the valve clearances are correctly adjusted,
the cylinder compression pressures are
correct, the ignition timing is correct (where
adjustable), and that the engine breather
hoses are clear and undamaged, referring to
Chapters 1, 2 and 5 for further information.
2 If these checks fail to reveal the cause of
the problem, the vehicle should be taken to a
suitably-equipped Peugeot dealer for testing.
A wiring block connector is incorporated in
the engine management circuit, into which a
special electronic diagnostic tester can be
plugged. The tester will locate the fault quickly
and simply, alleviating the need to test all the
system components individually, which is a
time-consuming operation that also carries a
risk of damaging the ECU.

Adjustment

3 Experienced home mechanics with a
considerable amount of skill and equipment
(including a tachometer and an accurately

calibrated exhaust gas analyser) may be able
to check the exhaust CO level and the idle
speed. However, if these are found to be in
need of adjustment, the car must be taken to
a suitably-equipped Peugeot dealer for further
testing.
4 On both single-point fuel injection systems,
no adjustment of the CO level and idle speed
is possible, these being under the complete
control of the ECU. Should the idle speed or
exhaust gas CO level be incorrect, then a fault
is likely to be present in the fuel injection
system.

11 Mono-Jetronic A2.2 system

components - removal and
refitting

3

Note: Check the availability of individual
components with your Peugeot dealer before
dismantling.

Fuel pressure regulator

Note: Refer to the warning note in Section 1
before proceeding.
1 The fuel pressure regulator (consisting of a
valve operated by a spring-loaded diaphragm
and a metal cover) is secured by four screws
to the top of the throttle body (see
illustration). Although the unit can be
dismantled for cleaning, if required (once the
air inlet trunking and the fuel injector wiring
clip have been removed for access), it should
not be disturbed unless absolutely necessary.
2 Note that the regulator assembly is only
available as part of the complete throttle body
assembly; no individual components can be
renewed separately.
3 If the regulator cover is removed, note its
orientation on the throttle body before
removal, to ensure correct refitting.

Fuel injector

Note: Refer to the warning note in Section 1
before proceeding. If a faulty injector is
suspected, before condemning the injector, it
is worth trying the effect of one of the
proprietary injector-cleaning treatments.
4 Disconnect the battery negative lead.
5 Remove the air inlet trunking from the top of
the throttle body.
6 Remove the Torx screws securing the
injector wiring connector to the top of the
throttle body, then carefully lift off the
connector (see illustrations).
7 Withdraw the injector (see illustration).
Recover and discard the injector sealing rings.
8 Refitting is the reverse of the removal
procedure, noting the following points.

a) Always renew both sealing rings: apply a

smear of grease to each ring, to ease
injector refitting.

b) Ensure that the injector is refitted so that

its connector pins align with the
connector when the connector is
correctly located on the top of the throttle
body.

Fuel system - single-point fuel injection engines  4B•3

4B

11.1  Fuel injector wiring clip (A), and fuel

pressure regulator securing screws (B) -

Mono-Jetronic A2.2 system

c) Before refitting the injector securing

screw, apply a few drops of a suitable
thread-locking compound to the threads.

d) On completion, switch on the ignition and

check carefully for signs of fuel leaks; if

any signs of leakage are detected the
problem must be rectified before the
engine is started.

Inlet air temperature sensor

9 The sensor is located in the fuel injector
wiring connector, and is available only as part
of the connector assembly. To remove the
connector assembly, proceed as follows.
10 Disconnect the battery negative lead.
11 Remove the air trunking from the top of
the throttle body, then unscrew the three
securing nuts, and remove the sealing ring.
Recover the O-ring (see illustrations).
12 Release the securing clips, separate the
two halves of the fuel injector wiring
connector, then release the wiring from the
clip on the top of the throttle body (see
illustrations).
13 Remove the Torx screw securing the fuel

injector wiring connector to the top of the
throttle body, then carefully lift off the
connector (see illustration).

Idle speed control motor

14 Disconnect the battery negative lead.
15 Release the securing clip, and disconnect
the wiring plug from the motor (see
illustration).
16 Unscrew the securing screws, and
withdraw the motor from the throttle body
assembly (see illustration).
17 Refitting is the reverse of the removal
procedure. Note that the motor will reset itself
as soon as the engine is restarted.

Throttle switch

18 The throttle switch is accurately matched
on the throttle valve during manufacture - it is
not adjustable and must not be disturbed.

4B•4 Fuel system - single-point fuel injection engines

11.6a  Remove the Torx screw . . .

11.6b  . . . and lift off the wiring connector

11.7  Withdrawing the fuel injector

11.12b  . . . then release wiring from clip

11.13  Intake air temperature sensor

(arrowed)

11.15 Disconnecting wiring plug from idle

speed control motor (arrowed)

11.11a  Remove the sealing ring . . .

11.11b . . . and recover the O-ring

11.12a  Separate the two halves of fuel

injector wiring connector . . .

11.16 Unscrewing an idle speed control

motor securing screw

19 Do not attempt to adjust the throttle
switch setting or that of the stop screw on the
throttle valve external linkage; if the accurately
matched relationship between these
components is lost, the components must be
replaced. At the time of writing this means
renewing the entire throttle body assembly.

Throttle body

Note: Refer to the warning note in Section 1
before proceeding.
20 Disconnect the battery negative lead.
21 Remove the air inlet trunking from the top
of the throttle body.
22 Disconnect the throttle cable (see Sect-
ion 3).
23 Release the securing clips, and
disconnect the wiring plugs from the fuel
injector, the idle speed control motor, and the
throttle switch (see illustrations).
24 Disconnect the fuel hoses from the unions
on the throttle body (refer to Section 4). Plug
the open ends of the hoses, to prevent dirt
ingress and further fuel loss. Take note of the
connections, and label them to ensure correct
refitting.
25 Disconnect the vacuum hoses and pipes
from the throttle body unions (see
illustration). Label the hoses and pipes so
that they can be correctly reconnected on
refitting.
26 Remove the screws securing the throttle
body to the inlet manifold, then withdraw the
assembly  (see illustration). Recover the
gasket, and discard it.

27 If desired, the throttle body upper and
lower sections may be separated by removing
the securing screws. Note that a new gasket
must be fitted on reassembly. As noted
previously, do not disturb the throttle switch.
The fuel inlet and return unions may be
unscrewed from the throttle body, and the
vacuum hose unions may be detached, but
note that new sealing rings must be fitted on
reassembly.
28 Refitting is the reverse of the removal
procedure, noting the following points.

a) Renew all gaskets and seals, and use

suitable thread-locking compound where
applicable.

b) Check the throttle cable operation and

adjustment (Section 3).

c) Ensure that all vacuum hoses and pipes

are correctly reconnected, as noted
before removal.

d) Ensure that the fuel hoses are correctly

reconnected. The direction of fuel flow is
indicated by arrows cast into the throttle
body next to each union.

e) On completion, switch on the ignition,

and check for signs of fuel leaks from all
disturbed unions. If any signs of leakage
are detected, the problem must be
rectified before the engine is started.

Coolant temperature sensor

Refer to Chapter 3, Section 7.

Electronic control unit (ECU)

29 The ECU is located behind the facia, to
the right of the steering column.

30 Disconnect the battery negative lead.

31 For improved access, remove the driver’s

side lower facia panel. The panel is secured

by four screws, and a single bolt.

32 Remove the nuts securing the ECU

bracket to the facia, then lower the assembly.

Withdraw the ECU from the bracket (see

illustration).

33 Release the securing clip, or remove the

securing screws, as applicable, and

disconnect the wiring plug (see illustration).

34 Refitting is a reversal of removal, but

ensure that the wiring plug is securely

reconnected, and where applicable, ensure

that the ECU locates correctly in the bracket.

Fuel injection system fuses and
relays

35 The relays are generally mounted on the

left-hand side of the engine compartment

bulkhead. The relays may be mounted on

individual brackets, or on later models, in a

plastic box.

36 Most of the fuses are located in the main

fusebox inside the car, although on certain

models, additional fuses may be located in a

small fusebox mounted at the front left-hand

corner of the engine compartment.

37 The number and type of fuses and relays

fitted will depend on engine type and exact

vehicle specification.

Fuel system - single-point fuel injection engines  4B•5

4B

11.23a  Disconnecting the wiring plug from

the fuel injector . . .

11.23b . . . and the throttle switch

11.25 Vacuum hose connection to throttle

body (arrowed)

11.26 Throttle body securing screws

(arrowed)

11.32  Removing the ECU from its bracket.

Note securing lug (arrowed)

11.33  Disconnecting the ECU wiring plug

12 MMFD Mono-point G5 and

G6 system components -
removal and refitting

3

Note: Check the availability of individual
components with your Peugeot dealer before
dismantling.

Fuel pressure regulator

1 Refer to Section 11, Paragraphs 1 to 3
noting the revised component arrangement
(see illustration).

Fuel injector

Note: Refer to the warning note in Section 1
before proceeding. If a faulty injector is
suspected, before condemning the injector, it
is worth trying the effect of one of the
proprietary injector-cleaning treatments. Note
that at the time of writing, the injector does
not appear to be available separately from the
throttle body upper section assembly.
2 Disconnect the battery negative lead.
3 Remove the air inlet trunking from the top of
the throttle body.
4 Release the securing clip, and disconnect
the injector wiring plug (see illustration).
5 Remove the Torx screw securing the
injector retainer plate to the top of the throttle
body (see illustration), lift off the retainer,
then withdraw the injector. Recover and
discard the injector sealing rings (check to
ensure that new sealing rings can be obtained
before discarding the old ones).
6 Refitting is the reverse of the removal
procedure, noting the following points.

a) Always renew both sealing rings; apply a

smear of grease to each, to ease injector
refitting.

b) Refit the injector so that its wiring

terminals point towards the front of the
vehicle, and locate the edge of the

retainer securely in the groove at the top
of the injector.

c) Before refitting the injector securing

screw, apply a few drops of a suitable
thread-locking compound to the threads.

d) On completion, switch on the ignition,

and check carefully for signs of fuel leaks;
if any signs of leakage are detected, the
problem must be rectified before the
engine is started.

Throttle switch

7 Disconnect the battery negative lead.
8 Disconnect the wiring plug, and disconnect
the wiring plug from the switch.
9 Remove the two securing screws and
withdraw the switch.
10 Refitting is a reversal of removal, noting
the following points.

a) Before refitting the switch, ensure that the

throttle valve is fully closed.

b) Ensure that the switch wiper engages

correctly with the throttle shaft.

Idle speed control valve (MMFD
G5 system)

11 For improved access, remove the air
cleaner trunking.

12 Disconnect the battery negative lead.
13 Release the securing clip, and disconnect
the wiring plug from the valve.
14 Loosen the securing clamps, and
disconnect the air hoses from the valve. Note
the locations of the hoses to ensure correct
refitting.
15 Remove the securing screws, and
withdraw the valve.
16 Refitting is a reversal of removal, noting
that the arrows cast on the valve unions
indicate the direction of airflow through the
valve. Ensure that the hoses are securely
refitted, to prevent air leaks.

Idle speed control motor (MMFD
G6 system)

Note: At the time of writing, it was not clear
whether the motor is available separately from
the throttle body assembly. It is advisable to
seek the advice of a Peugeot dealer before
deciding on the course of action to be
followed if the motor is thought to be faulty.
17 For improved access, remove the air inlet
trunking.
18 Disconnect the battery negative lead.
19 Release the securing clip, and disconnect
the wiring plug from the motor.
20 Remove the two securing screws, then
withdraw the motor. Recover and discard the
sealing ring (check to ensure that a new
sealing ring can be obtained before
discarding the old one).
21 Refitting is a reversal of removal bearing
in mind the following points.

a) Always fit a new sealing ring, greasing it

lightly to ease installation.

b) The control motor will be reset by the

ECU as soon as the engine is restarted.

c) Apply suitable thread-locking compound

to the securing screw threads before
refitting.

4B•6 Fuel system - single-point fuel injection engines

12.5  Fuel injector retaining plate securing

screw (arrowed)

12.1  Fuel pressure regulator (A) and fuel injector wiring plug (B)

12.4  MMFD G6 fuel injection system throttle body assembly

1 Fuel injector wiring connector
2 Fuel pressure regulator

3 Idle speed control motor
4 Throttle switch

Inlet air temperature sensor

22 The sensor is screwed into the top of the
inlet manifold.
23 Disconnect the battery negative lead.
24 Release the securing clip, and disconnect
the wiring plug from the sensor.
25 Unscrew the sensor and withdraw it.
26 Refitting is a reversal of removal.

Throttle body

Note: Refer to the warning note in Section 1
before proceeding.
27 Disconnect the battery negative lead.
28 Remove the air inlet trunking from the top
of the throttle body.
29 Disconnect the throttle cable (see Sec-
tion 3).
30 Release the securing clips, then
disconnect the wiring plugs from the fuel
injector (remove the rubber throttle
body/trunking seals to release the wiring),
throttle switch, and the idle speed control
motor (MMFD G6 system only).
31 Disconnect the fuel hoses from the unions
on the throttle body, labelling the hoses to
ensure correct refitting. Plug the open ends of
the hoses, to prevent dirt ingress and further
loss of fuel.
32 Disconnect the vacuum pipes and hoses
from the throttle body unions. Label the hoses
so that they can be correctly reconnected.
33 Unscrew the studs securing the throttle
body to the inlet manifold, and withdraw the
assembly. Recover and discard the gasket.
34 If desired, the two halves of the throttle

body (upper and lower) can be separated by
removing the securing screws. Note that in
this case, a new gasket must be used on
reassembly.
35 Refitting is a reversal of removal, bearing
in mind the following points.

a) Renew all disturbed gaskets and seals,

and use suitable thread locking
compound where necessary.

b) Check the throttle cable operation and

adjustment (Section 3).

c) Ensure that all vacuum hoses and pipes

are correctly reconnected as noted before
removal.

d) When reconnecting the manifold absolute

pressure sensor hose, ensure that it is
routed so that it falls steadily from the
sensor to the throttle body. This is
necessary to prevent any fuel droplets
from entering the sensor (no fuel vapour
trap is fitted), allowing them to drain into
the throttle body instead.

e) Ensure that the fuel hoses are correctly

reconnected, as noted before removal.

f) On completion, switch on the ignition,

and check carefully for signs of fuel
leakage from all disturbed unions. If any
signs of leakage are detected the problem
must be rectified before the engine is
started.

Manifold absolute pressure
sensor

36 Disconnect the battery negative lead.
37 Release the securing clip, and disconnect

the wiring plug from the idle speed control
motor (MMFD G6 systems only).
38 Slacken the clamp (if fitted), and
disconnect the vacuum hose from the sensor.
39 Remove the securing screws and
withdraw the sensor, complete with bracket,
from the body front panel (or wing panel, as
applicable).
40 Refitting is a reversal of removal, but note
the following. When reconnecting the vacuum
hose to the sensor ensure that the hose is
routed so that it falls steadily from the sensor
to the throttle body. This is necessary to
prevent any fuel droplets from entering the
sensor (no fuel vapour trap is fitted), allowing
them to drain into the throttle body instead.

Coolant temperature sensor

Refer to Chapter 3, Section 7.

Electronic control unit (ECU)

Refer to Section 11, paragraphs 29 to 34.

Fuel injection system fuses and
relays

Refer to Section 11, paragraphs 35 to 37.

13 Inlet manifold - removal and

refitting

3

The procedure is essentially as described in

Part A, Section 11, but remove the throttle
body as described in Section 11 or 12 of this
Part and ignore any references to carburettor.

Fuel system - single-point fuel injection engines  4B•7

4B