Contents: Removing and installing the air… ↳ Removing and installing the fuel… ↳ Removing and installing the… ↳ Removing and installing fuel… ↳ Removal and installation of fuel… ↳ Removing and installing the fuel pump ↳ Removing and installing the fuel… ↳ Removing and installing the fuel… ↳
Removing and installing the air filter
Disconnect the negative cable from the battery. Loosen the clamp and remove the air duct connecting the air filter to the air flow meter. Remove the positive idle speed sensor and its gasket from the upper cover of the air filter. Loosen the six Phillips-head screws securing the air flow meter, but do not remove it. Loosen the clamping screw and remove the fuel filter. Loosen the two nuts securing the air filter housing, as well as the screw securing its lower mount to the inner wing panel. Remove the air intake hose secured to the lower part of the shield. Move the upper cover of the filter to the side, remove the air flow meter and move it to the side, remove the upper cover and filter element. Remove the air filter. Clean the filter before installation. Install in the reverse order of removal. Make sure the air flow meter gasket is installed correctly
NOTE: From mid-September 1980, on vehicles produced in Sarlouis (index SL), a 3 mm high spacer was installed between the air filter and the thermostat.
Removing and installing the fuel dispenser
Disconnect the negative cable from the battery. Place a rag under the hose fitting from the control pressure regulator, release it to relieve pressure in the system. Disconnect all fuel lines from the dispenser-distributor (fig. 2.114). Loosen the three mounting bolts and remove it together with the air flow meter. Before installation, clean the mating surfaces and fittings. Install and secure the mixture regulator assembly between the air flow meter and the metering distributor. Connect all hoses to the metering distributor, installing new washers on each side of the fitting. Do not use excessive force when tightening the fittings. Connect the negative battery cable. Check the fuel pressure and engine idle speed.
REMOVAL AND INSTALLATION OF THE CONTROL PRESSURE REGULATOR
Disconnect the negative battery cable and connector block 1 (fig. 2.115) regulator. Place a rag under the fuel line fittings, relieve the pressure and remove these fuel lines. Unscrew the two Allen bolts and remove the control pressure regulator. Before installation, wipe the mating surfaces and fittings. Install the regulator in place and secure it with two bolts, apply sealant to the screw heads. Install two new washers on the ends of the pipes, one under the fitting, one under the screw. Do not apply excessive force when tightening the fittings. Connect the connector block and the negative cable of the battery.
Removing and installing the starting injector
Disconnect the negative cable from the battery and connector block 1 (Fig. 2.116).
Disconnect the nipple and the fuel supply pipe, having first relieved the fuel pressure. Unscrew the two screws 2 securing the injector and remove it. Before installation, wipe the mating surfaces. Install a new gasket, tighten the injector mounting screws and apply sealant to them. Install two new washers at the end of the pipeline, one under the nipple, one under the screw. Do not apply excessive force when tightening the nipple. Connect the connector block and the negative cable of the battery. Start the engine and check the tightness of the fuel system.
Removing and installing the additional air supply valve
Disconnect the negative cable from the battery, connector block 3 (Fig. 2.117) and two hoses from the valve.
Unscrew the two Allen-head bolts and remove the valve. Install in the reverse order of removal. Apply sealant to the screws.
Removing and installing fuel injectors
Disconnect the negative cable from the battery. Unscrew the fuel supply fittings to the injectors. Unscrew the holders' mounting screws and remove the injectors. Clean all fittings, check the position of the injector sealing gaskets, install the injectors and secure them with holders. Connect the fuel lines and the battery.
Removal and installation of fuel injector lines
Flexible hoses of injectors are connected to metal tubes by couplings, disassembling which is prohibited. In addition, on some XR 3i vehicles, the tips of the fittings are connected to plastic flexible hoses by special connectors, disassembling which is also prohibited. Before removing the high-pressure fuel lines, disconnect the negative cable of the battery and disconnect the fuel lines from the injectors, then disconnect them from the dispenser-distributor and remove the fuel lines as a set. Before installation, thoroughly clean the fitting connections. Make sure that the fuel lines are not twisted or damaged. Install in the reverse order of removal, installing two new gaskets on each fitting, do not apply excessive force when tightening. Connect the negative wires to the battery.
Removing and installing the fuel pump
Place the car on an inspection pit or lift. Disconnect the negative cable from the battery. Under the nipple 4 (fig. 2.114) place a rag under the fuel line from the control pressure regulator and relieve the pressure in the system. loosening the fitting. Use a clamp to pinch the fuel supply hose to the fuel pump so that fuel does not drain into the tank after disconnecting the fuel line and so as not to damage the fuel line. Place a container under the fuel supply fitting, remove the clamp and the fuel line. Plug the fuel line hole. Disconnect both connector blocks from the pump and disconnect the pressure fuel line from it. Unscrew the mounting nut to the bracket and remove the pump. Before installation, thoroughly clean the fittings and couplings. Install the pump in place, making sure that the rubber coupling is installed correctly. Connect the pressure hose and both connectors, then the fuel supply hose and remove the clamp from the hose.
Lower the vehicle and tighten the fuel supply nipple into the control pressure regulator. Connect the battery, start the engine and check the fuel system for leaks.
Removing and installing the fuel pressure accumulator
Place the vehicle on a ditch or lift. Disconnect the negative cable from the battery. Place a rag under the nipple 2 (fig. 2.114) supply fuel to the control pressure regulator and, slowly releasing it, relieve the pressure in the system. Place a container under the accumulator fittings and unscrew them. Unscrew the accumulator bracket fastening screw and remove it together with the accumulator. Before installation, wipe the fittings, install the accumulator in the reverse order of removal, start the engine and check the tightness of the connections.
Removing and installing the fuel filter
Disconnect the negative cable from the battery. Place a rag under the nipple 2 (fig. 2.114) supply fuel to the control pressure regulator and, slowly releasing it, release the pressure. Place a container under the fuel filter fittings and unscrew them. Loosen the filter mounting clamp and remove the filter. Install in the reverse order of removal, start the engine and check the tightness of the connections.