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:
- Crafting table
- Fixing clamps
Withdrawal
All cars
WARNING: Do not smoke or walk with a lit cigarette or any type of open flame while working on or near fuel related items. In such situations, there are always highly flammable mixtures that can ignite. Failure to follow these instructions may result in injury.
1. Disconnect the battery and remove the battery shelf. Refer to Section 414-01 for more information.
2. Drain the coolant from the cooling system. Refer to Section 303-03 for more information.
3. Remove the air filter. See Section 303-12 for more information.
4. Loosen the nuts of the top support of the rack assembly with the spring three turns (at both sides).
5. Remove the engine top cover.
6. Remove the inlet and outlet pipes of the charge air cooler.
7. Disconnect the charge air cooler duct.
8. Disconnect the plug connector of the air intake temperature sensor (IAT).
9. Remove the charge air cooler.
10. Remove the final pipeline of the air filter.
11. Remove the air intake pipe.
12. Disconnect the glow plug power wire from the glow plug wire terminal block.
13. Disconnect the glow plug wire terminal block.
14. Disconnect the dipstick of the oil level indicator and secure it to the side.
15. Disconnect the vacuum pipeline from the vacuum pump of the vacuum amplifier of brakes.
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
18. Disconnect the plug connector of the fuel high pressure sensor.
All cars
19. Using the special tool, disconnect the coolant hoses from the thermostat housing and from the coolant distribution pipe.
20. Remove a cover of electric sockets of the generator.
21. Disconnect the alternator connector and disconnect the alternator power wire.
22. Disconnect the vacuum hose from the vacuum diaphragm unit.
23. Disconnect the engine wiring harness.
Vehicles with Common Rail Fuel Injection
24. Disconnect the plug connector of the injector control module.
25. Disconnect the vacuum hose from the EGR valve (EGR).
26. Disconnect the EGR vacuum hose.
27. Disconnect the electronic vacuum control valve support bracket from the intake manifold and position it to the side.
Vehicles with EGR cooler
28. Using the special tool, disconnect the upper coolant hose from the EGR cooler.
Vehicles 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 pipe from the power steering pump.
32. Disconnect the power steering high pressure pipe bracket from the timing belt cover stud.
33. Disconnect the power steering high pressure pipe bracket from the engine lift lug.
34. Disconnect the power steering high pressure pipe from the bracket.
35. Disconnect the power steering reservoir and secure it to the side. Let the liquid drain into a suitable container.
36. Disconnect the supply and return fuel lines from the appropriate bracket.
37. Disconnect the fuel supply and return quick couplings. Refer to Section 310-00 for more 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 connector and disconnect the cooling fan wiring harness from the cooling fan shroud.
Vehicles with an air conditioning system.
41. Using collars, fix the heat exchanger of system of air conditioning.
All cars
42. Remove the accessory drive belt. Refer to Section 303-05 for more information.
43. Disconnect the horn connector and disconnect the horn wiring harness.
Vehicles with air conditioning
44. Disconnect the air conditioning compressor connector and disconnect it from the compressor.
45. Remove the air conditioning compressor (four bolts). Use the zip ties 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 more 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 nut in place to prevent damage to the ball joint stud.
Loosen the left tie rod end nut.
52.
CAUTION: Using a soft cloth, cover the ball joint seal.
Using the special tool, disconnect the tie rod end. Discard the nut as it is no longer needed.
53. Disconnect the starter connector and disconnect the power cable.
54. Remove the radiator support bracket (left side shown).
55. Disconnect the shift cables from the gearbox in the block with the drive axle.
- 1.Disconnect the shift cable from the 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 selector lever.
- 4. Pre-tighten the support bushings by turning them counterclockwise and remove the cable assembly from the bracket.
- 5.Disconnect the adjusting mechanism by pressing it.
56.
CAUTION: Excessive kinking of the flexible exhaust pipe can cause damage resulting in failure of the exhaust system.
Support the flexible exhaust pipe with a support clamp or a suitable bar.
57. Disconnect the flexible exhaust pipe from the exhaust system. Discard the nuts as they are no longer needed.
58. Remove the engine mount.
59.
CAUTION: Secure the axle shaft to prevent damage to the CV joints. The internal constant velocity joint should not be deflected by more than 18 degrees. External hinge - at an angle exceeding 45 degrees.
CAUTION: Check that the shaft seal is not damaged.
CAUTION: Close the transaxle to prevent oil from escaping and dirt from entering.
Detach the right axle shaft and secure it to the side.
- Remove the intermediate bearing cap and related 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 CV joints. The internal constant velocity joint should not be deflected by more than 18 degrees. External hinge - at an angle exceeding 45 degrees.
CAUTION: Check that the shaft seal is not damaged.
CAUTION: Close the transaxle to prevent oil from escaping and dirt from entering.
Using the special tool, disengage the left axle shaft from the transaxle and secure it out of the way. Allow the oil to drain into a suitable container.
61. Disconnect the high pressure line from the clutch slave cylinder.
- 1.Remove the clip.
- 2.Disconnect the bracket together with the O-ring.
62. Disconnect the starter harness bracket and engine ground cable from the transaxle case.
63.
WARNING: Place the engine/gearbox assembly in the drive axle assembly on blocks of wood. Failure to follow these instructions may result in injury.
CAUTION: Support the engine under the oil sump flange.
Using suitable clamps, secure the engine/gearbox assembly to the drive axle assembly on a workbench.
64. Remove the rear engine mount.
Vehicles manufactured up to 04.2001
65. Remove the front engine mount.
Vehicles manufactured since 04.2001
66. Remove the front engine mount.
All cars
67. Raise the car and remove the engine assembly with the gearbox in the block with the drive axle.
68. Remove the gearbox in the block with the drive axle from the engine.
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