| 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 cowl panel grille.
For additional information, refer to: Cowl Panel Grille - Vehicles Built Up To: 03/2007 (501-02 Front End Body Panels, Removal and Installation).
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Remove the battery tray.
For additional information, refer to: Battery Tray - 1.6L Duratorq-TDCi (DV) Diesel/1.8L Duratorq-TDCi (Lynx) Diesel/2.0L Duratorq-TDCi (DW) Diesel (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 front halfshafts.
For additional information, refer to: Halfshaft RH (205-04, Removal and Installation) /
Halfshaft LH (205-04, Removal and Installation).
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Remove the left-hand fender splash shield. | 9. Remove the components in the order indicated in the following illustration(s) and table(s). 5 - Heater core coolant hose 6 - Intake air shutoff throttle intake pipe 7 - Turbocharger outlet pipe 12 - Brake booster vacuum hose 18 - Reversing lamp switch electrical connector Removal Details Item 1 : Coolant hose | | -
Using the special tool, remove the coolant hose and detach the coolant expansion tank from the wheelhouse panel and position it to one side. | Item 2 : Fuel supply line | | -
Disconnect the fuel supply line.
For additional information, refer to: Quick Release Coupling (310-00 Fuel System - General Information, General Procedures).
| Item 3 : Battery junction box (BJB) electrical connector | | -
CAUTION:Do not bent the BJB electrical connector. Unlock and disconnect the BJB electrical connector. | Item 8 : Exhaust flexible pipe | | -
Remove the exhaust flexible pipe.
For additional information, refer to: Exhaust Flexible Pipe (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 | | -
File a flat across the PCM security bracket welded nut. | | | -
Remove the PCM security bracket sheer bolt. - Drill a 2 mm pilot hole 3 mm from the outer edge of the security bracket welded nut at an angle of approximately 2 degrees.
- Drill a 5 mm hole in the security bracket welded nut and remove the security bracket sheer bolt.
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Slide the security bracket off of the PCM. | | | -
Disconnect the PCM electrical connectors in the sequence shown. | 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 13 : Gearshift cables | | -
Detach the gearshift cables from the selector mechanism. - Press the selector cable catch and detach the selector cable from the selector lever.
- Press the gearshift cable catch and detach the gearshift cable from the gear lever.
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Detach the gearshift cables from the abutment. - Release the selector cable by turning the catch counter-clockwise and detach from the abutment.
- Release the gearshift cable by turning the catch counter-clockwise and detach from the abutment.
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CAUTION:If brake fluid is spilt on the paintwork, the affected area must be immediately washed down with cold water. CAUTION:Cap the clutch slave cylinder supply line to prevent fluid loss or dirt ingress. Disconnect the clutch slave cylinder supply line. - Detach the clutch slave cylinder supply line from the bracket.
| Item 14 : Radiator to thermostat housing coolant hose | | -
Disconnect the radiator to thermostat housing coolant hose | Item 15 : Thermostat housing degas hose | | -
Disconnect the degas hose from the thermostat housing. | Item 16 : 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. Using suitable securing straps, secure the engine and transaxle assembly on the workshop table. | | | -
Remove the engine rear mount. | Item 17 : Engine front mount | | -
Remove the engine front mount. | Item 19 : 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) /
Starter Motor - 1.6L Duratorq-TDCi (DV) Diesel, Vehicles With: Automatic Transaxle (303-06 Starting System, Removal and Installation).
| Item 20 : Transaxle retaining bolts | | -
Remove the transaxle upper retaining bolts. | | | -
Remove the transaxle lower retaining bolts. | |
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