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In-vehicle Repair|Disassembly > < Timing Chain

Ikon 1999 (01.2000-)

Engine - 1.3L Duratec-8V (Rocam)/1.6L Duratec-8V (Rocam) - Engine Ikon 1999 (01/2000-)
Removal

Special Tool(s)

Remover/Installer, Hose Clamp

303-397 (24-003)

Remover, Halfshaft

308-237 (16-087)

Remover, Halfshaft

308-256 (16-089)
General Equipment
Retaining strap
Assembly stand

Removal

All vehicles
  1. General notes.
    • The locations of the engine mountings and the engine support insulators are described looking from the transaxle to the engine.
    • Steps which apply only to particular variants are indicated with a note.
    • If necessary, cut the cable ties and install new during installation.
  1. Remove the battery. For additional information, refer to Section  414-01 Battery, Mounting and Cables.

  1. Remove the battery tray.
    1. Cut the cable ties.
    1. Remove the bolts.

  1. Remove the air cleaner intake pipe.

  1. Remove the hoses.
    1. EVAP solenoid valve vacuum hose
    1. Positive crankcase ventilation hose
    1. Brake booster vacuum hose

  1. WARNING:
    WARNING:Escaping fuel. Observe the safety regulations for working with fuel.
    Disconnect the fuel lines.

  1. Remove the accelerator cable.
    1. Remove the clip and pull the cable from the bracket.
    1. Unhook the inner cable.

  1. WARNING:
    WARNING:Danger of scalding if the engine is warm.
    Drain the coolant (shown from below).
    • Screw in the drain plug after draining.

  1. Using the special tool, disconnect the coolant hoses from the coolant flow control housing.

  1. Remove the right-hand coolant hose bracket.

  1. Remove the left-hand coolant hose bracket.

  1. Disconnect the ground cable, the electrical connectors and the transmission breather.
    1. Disconnect the ground cable.
    1. Disconnect the generator electrical connector.
    1. Disconnect the starter motor electrical connector.
    1. Disconnect the transmission breather.

  1. Disconnect the electrical connectors.
    1. Disconnect the heated oxygen sensor (HO2S).
    1. Disconnect the powertrain control module (PCM).
    1. Disconnect the electronic ignition (EI) coil.
    1. Disconnect the vehicle speed (VSS) sensor.

  1. Disconnect the reversing lamp switch electrical connector.

  1. Disconnect the speedometer drive cable from the transaxle.

  1. CAUTION:
    CAUTION:If brake fluid is spilt on the paintwork, the affected area must be immediately washed down with cold water.
    CAUTION:
    CAUTION:Cap the clutch slave cylinder supply line to prevent fluid loss and dirt ingress.
    Disconnect the clutch slave cylinder hydraulic line.

  1. Disconnect the cooling fan electrical connectors.

  1. Remove the cooling fan.
    • First slide the fan upwards and then remove it from underneath the vehicle.

  1. NOTE:
    NOTE:Use an Allen key to stop the piston rod from turning.
    Loosen the suspension strut retaining nut five turns on both sides (right-hand side shown).

  1. Remove the accessory drive belt.
    • Turn the belt tensioner clockwise and slip the belt off the pulleys.
Vehicles with power steering
  1. Detach the power steering pump from the retaining bracket. For additional information, refer to Section  211-02 Power Steering.
All vehicles
  1. Raise and support the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.

  1. Remove the accessory drive belt cover.
Vehicles with air conditioning
  1. Remove the A/C compressor and secure it to the radiator crossmember.
All Vehicles
  1. Using the special tool, disconnect the coolant hose.

  1. Disconnect the catalytic converter from the exhaust manifold and position it to one side.
    1. Remove the nuts.
    1. Detach the exhaust hanger insulator.
    • Remove and discard the gasket.

  1. Disconnect the lower arm from the wheel knuckle on both sides (left-hand side shown).

  1. Remove the exhaust lower heat shield.

  1. CAUTION:
    CAUTION:Secure the halfshaft to prevent damage to the constant velocity (CV) joints. The inner CV joint must not be bent more than 18 degrees. The outer CV joint must not be bent more than 45 degrees.
    CAUTION:
    CAUTION:Do not damage the halfshaft seal.
    NOTE:
    NOTE:Cap the transaxle to prevent oil loss and dirt ingress.
    Using the special tool, detach the right-hand halfshaft from the transaxle and secure it to one side.
    • Allow the oil to drain into a suitable container.
    • Discard the snap ring.

  1. CAUTION:
    CAUTION:Secure the halfshaft to prevent damage to the CV joints. The inner CV joint must not be bent more than 18 degrees. The outer CV joint must not be bent more than 45 degrees.
    CAUTION:
    CAUTION:Do not damage the halfshaft seal.
    NOTE:
    NOTE:Cap the transaxle to prevent oil loss and dirt ingress.
    Using the special tool, detach the left-hand halfshaft from the transaxle and secure it to one side.

  1. Disconnect the shift rod and gear shift stabilizer.
    1. Remove the shift rod.
    1. Remove the gearshift stabilizer.

  1. NOTE:
    NOTE:The engine roll restrictor is under tension.
    Remove the engine roll restrictor.

  1. Remove the coolant return hose.
  1. Position the assembly stand with wooden blocks on it under the vehicle.
  1. Carefully lower the vehicle until the engine and transaxle assembly is on the assembly stand.

  1. Secure the engine and transaxle assembly on the assembly stand with a retaining strap.

  1. Remove the engine rear mount.
    • Discard the nuts.

  1. Remove the engine front mount.
    • Discard the nuts.
  1. Move the assembly stand forward with the engine and transaxle assembly.

  1. Install an engine lifting eye.

  1. Disconnect the engine wiring harness electrical connectors.
    1. Remove the generator electrical connectors.
    1. Remove the oil pressure switch.
    1. Remove the crankshaft position (CKP) sensor.

  1. Disconnect the knock sensor (KS) electrical connector.

  1. Remove the starter motor and the transaxle left-hand flange bolt.

  1. Remove the transaxle right-hand flange bolts.

  1. Remove the transaxle lower flange bolts.

  1. Remove the transaxle upper flange bolt.
  1. Remove the transaxle.

In-vehicle Repair|Disassembly > < Timing Chain