| Removal Special Tool(s) | | Lifting Bracket, Engine 303-122 | | | Remover/Installer, Hose Clamp 303-397 | General Equipment Engine hoist Securing straps Workshop table Worldwide Diagnostic System (WDS) WARNING:Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related components. Highly flammable vapors are always present and may ignite. Failure to follow these instructions may result in personal injury. | | -
Using datalogger in Worldwide Diagnostic System (WDS), check that the fuel pressure has dropped to zero and that the fuel temperature is below 30°C. | | | -
Drain the cooling system.
For additional information, refer to: Cooling System Draining, Filling and Bleeding (303-03D Engine Cooling - 1.6L Duratorq-TDCi (DV) Diesel, General Procedures).
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Remove the battery tray.
For additional information, refer to: Battery Tray (414-01 Battery, Mounting and Cables, Removal and Installation).
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Remove the air cleaner.
For additional information, refer to: Air Cleaner - 1.6L Duratorq-TDCi (DV) Diesel (303-12 Intake Air Distribution and Filtering, Removal and Installation).
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Remove the cooling fan motor and shroud.
For additional information, refer to: Cooling Fan Motor and Shroud (303-03D Engine Cooling - 1.6L Duratorq-TDCi (DV) Diesel, Removal and Installation).
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Remove the charge air cooler.
For additional information, refer to: Charge Air Cooler - 1.6L Duratorq-TDCi (DV) Diesel (303-12 Intake Air Distribution and Filtering, Removal and Installation).
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Remove the halfshafts. For additional information, refer to: (205-04 Front Drive Halfshafts) Front Halfshaft LH (Removal and Installation), Front Halfshaft RH (Removal and Installation). | | | -
Remove the left-hand headlamp assembly.
For additional information, refer to: Headlamp Assembly (417-01 Exterior Lighting, Removal and Installation).
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Remove the left-hand fender splash shield. | 10. Remove the components in the order indicated in the following illustration(s) and table(s). 3 - Engine wiring harness electrical connector 4 - Brake booster vacuum line 12 - Battery junction box (BJB) electrical connector 13 - Coolant hoses to heater core 14 - Battery tray support bracket 15 - Glow plug relay electrical connector 17 - Exhaust gas recirculation (EGR) vacuum lines 18 - Power steering pump electrical connector 21 - Gearshift cables retaining brackets Removal Details Item 1 : Coolant expansion tank | | -
Using the special tool, remove the coolant expansion tank to heat exchanger coolant hose and detach the coolant expansion tank from the wheelhouse panel and position it to one side. | Item 2 : Fuel line quick release coupling | | -
Disconnect the fuel supply line quick release coupling.
For additional information, refer to: Quick Release Coupling (310-00 Fuel System - General Information, General Procedures).
| Item 6 : Turbocharger outlet pipe | | -
CAUTION:The turbocharger must be protected from ingress of foreign material. Failure to follow this instruction may cause premature failure of the turbocharger. Using a suitable lint-free material cover the turbocharger outlet pipe to prevent ingress of foreign material. | Item 7 : Charge air cooler outlet hose | | -
CAUTION:The charge air cooler outlet hose retaining clip is moulded to the charge air cooler outlet hose. Do not attempt to detach the retaining clip from the the hose. Failure to follow this instruction may cause damage to the charge air cooler outlet hose. Detach the charge air cooler outlet hose. | Item 8 : Exhaust flexible pipe | | -
Remove the exhaust flexible pipe.
For additional information, refer to: Exhaust Flexible Pipe - 1.4L Duratorq-TDCi (DV) Diesel/1.6L Duratorq-TDCi (DV) Diesel (309-00 Exhaust System, Removal and Installation).
| Item 9 : Engine support insulator | | -
Remove the engine support insulator retaining bolts. - Discard the engine support insulator to transaxle retaining bolt.
| Item 10 : Powertrain control module (PCM) electrical connectors | | -
Disconnect the powertrain control module. For additional information, refer to: Powertrain Control Module (PCM) - 1.6L Duratorq-TDCi (DV) Diesel (303-14 Electronic Engine Controls, Removal and Installation). | Item 11 : Air conditioning (A/C) compressor | | -
Disconnect the A/C compressor electrical connector. | | | -
Detach the A/C compressor from the mounting bracket and secure it to one side. | Item 16 : Thermostat housing coolant hoses | | -
Using the special tool, disconnect the radiator lower coolant hose from the thermostat housing. | | | -
Detach the coolant expansion tank to thermostat coolant hose. - Release the locking tangs.
- Detach the coolant hose and seal.
| Item 20 : Gearshift cables | | -
Detach the gearshift cables from the transaxle. - Detach the gearshift cable and the selector cable from the selector levers.
- Turn the abutment sleeves clockwise and detach the cables from the bracket.
| Item 22 : Clutch slave cylinder supply line | | -
CAUTION:If brake fluid is spilt on the paintwork, the affected area must be immediately washed down with cold water. Disconnect the clutch slave cylinder supply line. - Detach the clutch slave cylinder supply line from the retaining bracket.
| Item 23 : Engine rear mount | | -
CAUTION:Do not support the engine and transaxle assembly directly on the oil pan. NOTE:Support the engine and transaxle assembly with suitable wooden blocks. | | | -
Remove the engine and transaxle assembly. | Item 25 : Starter motor | | -
Remove the starter motor.
For additional information, refer to: Starter Motor - 1.6L Duratorq-TDCi (DV) Diesel (303-06 Starting System, Removal and Installation).
| Item 26 : Transaxle retaining bolts | | -
Remove the transaxle upper retaining bolts. | | | -
Remove the transaxle lower retaining bolts. | | | -
Detach the transaxle from the engine. | | | -
Using the special tool, attach the engine to the engine hoist. | |
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