Special tool
 | Ball joint puller 211-020 (13-006) |
 | Coolant Hose Clamp Remover/Installer 303-397 (24-003) |
 | Axle puller 308-192 (16-057) |
General equipment:
- Workbench
- Fixing clamps
Removal
All cars
WARNING: Do not smoke or carry a lighted cigarette or open flame of any type when working on or near fuel-related components. Highly flammable mixtures are always present in such situations and may ignite. Failure to follow these instructions may result in injury.
1. Disconnect the battery and remove the battery tray. For additional information, refer to Section 414-01.
2. Drain the coolant from the cooling system. Refer to Section 303-03 for additional information.
3. Remove the air cleaner. For additional information, refer to Section 303-12.
4. Loosen the nuts of the upper support of the strut assembly with the spring by three turns (on both sides).
5. Remove the top engine cover.
6. Remove the charge air cooler inlet and outlet pipes.
7. Disconnect the charge air cooler duct.
8. Disconnect the intake air temperature (IAT) sensor connector.
9. Remove the charge air cooler.
10. Remove the air cleaner outlet pipe.
11. Remove the air intake pipe.
12. Disconnect the glow plug power supply wire from the glow plug wire terminal block.
13. Disconnect the glow plug wire terminal block.
14. Disconnect the oil level indicator dipstick and secure it to the side.
15. Disconnect the vacuum line from the brake booster vacuum pump.
16. Using the special tool, disconnect the upper coolant hose from the thermostat housing.
17. Remove the thermostat housing. Discard the gasket as it is no longer needed.
Vehicles with common rail fuel injection system
18. Disconnect the high fuel pressure sensor connector.
All cars
19. Using the special tool, disconnect the cooling system hoses from the thermostat housing and from the coolant distribution line.
20. Remove the generator electrical connector cover.
21. Disconnect the generator plug and disconnect the generator power wire.
22. Disconnect the vacuum hose from the vacuum diaphragm unit.
23. Disconnect the engine wiring harness.
Vehicles with common rail fuel injection system
24. Disconnect the injector control module connector.
25. Disconnect the vacuum hose from the exhaust gas recirculation (EGR) valve.
26. Disconnect the EGR vacuum hose.
27. Disconnect the electronic vacuum control valve support bracket from the intake manifold and place it aside.
Cars with EGR cooler
28. Using the special tool, disconnect the upper coolant hose from the EGR cooler.
Cars without common rail fuel injection
29. Disconnect the vacuum hoses from the EGR valve and disconnect the corresponding plug connector.
30. Disconnect the high pressure fuel pump connector.
All cars
31. Disconnect the high pressure line from the power steering pump.
32. Disconnect the power steering high pressure line bracket from the timing belt cover stud.
33. Disconnect the power steering high pressure line bracket from the engine lifting eye.
34. Disconnect the power steering high pressure line from the bracket.
35. Disconnect the power steering fluid reservoir and secure it to the side. Allow the fluid to drain into a suitable container.
36. Disconnect the fuel supply and return lines from the corresponding bracket.
37. Disconnect the fuel supply and return line quick release couplings. Refer to Section 310-00 for additional information.
38. Using the special tool, disconnect the lower coolant hose from the expansion tank of the cooling system.
39. Remove the expansion tank.
40. Disconnect the cooling fan electric connector and disconnect the cooling fan wiring harness from the cooling fan housing.
Cars with air conditioning system.
41. Using clamps, secure the air conditioning system heat exchanger.
All cars
42. Remove the accessory drive belt. Refer to Section 303-05 for additional information.
43. Disconnect the horn connector and disconnect the horn wiring harness.
Cars with air conditioning system
44. Disconnect the air conditioning compressor plug and disconnect it from the compressor.
45. Remove the air conditioning compressor (four bolts). Use clamps to secure it to the side.
All cars
46. Using the special tool, disconnect the coolant hose from the oil cooler.
47. Using the special tool, disconnect the return hose from the power steering pump.
48. Remove the left front wheel and tire assembly. Refer to Section 204-04 for additional information.
49. Disconnect the anti-roll bar on the left side.
50.
CAUTION: Using a soft cloth, cover the ball joint seal.
Disconnect the lower control arms from the steering knuckles (left side shown).
51.
CAUTION: Leave the tie rod end retaining nut in place to protect the ball joint stud from damage.
Loosen the left tie rod end mounting nut.
52.
CAUTION: Using a soft cloth, cover the ball joint seal.
Using a special tool, disconnect the steering rod end. Discard the nut as it is no longer needed.
53. Disconnect the starter plug and disconnect the power supply wire.
54. Remove the radiator support bracket (left side shown).
55. Disconnect the gear shift cables from the transaxle.
- 1. Disconnect the shift cable from the gear shift lever.
- 2. Pre-tighten the support bushings by turning them counterclockwise and remove the cable assembly from the bracket.
- 3. Disconnect the selector cable from the gear selector lever.
- 4. Pre-tighten the support bushings by turning them counter-clockwise and remove the cable assembly from the bracket.
- 5. Disconnect the adjustment mechanism by pressing on it.
56.
CAUTION: Excessive bending of the flexible exhaust pipe may cause damage resulting in failure of the exhaust system.
Support the flexible exhaust pipe with a support clamp or suitable tire.
57. Disconnect the flexible exhaust pipe from the exhaust system. Discard the nuts as they are no longer needed.
58. Remove the engine support cushion.
59.
CAUTION: Secure the axle shaft to prevent damage to the constant velocity joints. The inner constant velocity joint should not be deflected more than 18 degrees. The outer constant velocity joint should not be deflected more than 45 degrees.
CAUTION: Make sure the axle shaft seal is not damaged.
CAUTION: Cover the transaxle to prevent oil leakage and dirt from entering.
Disconnect the right axle shaft and secure it to the side.
- Remove the intermediate bearing cover and associated locknuts and discard them as no longer needed.
- Allow the oil to drain into a suitable container.
60.
CAUTION: Secure the axle shaft to prevent damage to the constant velocity joints. The inner constant velocity joint should not be deflected more than 18 degrees. The outer constant velocity joint should not be deflected more than 45 degrees.
CAUTION: Make sure the axle shaft seal is not damaged.
CAUTION: Cover the transaxle to prevent oil leakage and dirt from entering.
Using the special tool, disconnect the left half shaft from the transaxle and secure it to the side. Allow the oil to drain into a suitable container.
61. Disconnect the high pressure line from the clutch slave cylinder.
- 1.Remove the clamp.
- 2. Disconnect the bracket together with the sealing ring.
62. Disconnect the starter wiring harness bracket and engine ground cable from the transaxle housing.
63.
WARNING: Support the engine and transaxle assembly on wooden blocks. Failure to follow these instructions may result in personal injury.
CAUTION: Support the engine under the oil pan flange.
Using suitable clamps, secure the engine and transmission assembly to the drive axle on the work bench.
64. Remove the rear engine mount.
Cars manufactured up to 04.2001.
65. Remove the front engine mount.
Cars manufactured since 04.2001.
66. Remove the front engine mount.
All cars
67. Raise the vehicle and remove the engine assembly with the gearbox in the block with the drive axle.
68. Remove the gearbox in block with the drive axle from the engine.
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