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In-vehicle Repair|Disassembly > < Valve Seals

Ikon 1999 (01.2000-)

Engine - 1.8L Endura-DE (Kent) Diesel - Engine Ikon 1999 (01/2000-)
Removal

Special Tool(s)

Remover, halfshaft

16-087 (16087)

Remover, halfshaft

16-089 (16089)

Engine Lifting Bracket

21-068A (21068A)

Cooling Hose Clamp Remover/Installer

24-003 (24003)
General Equipment
Assembly table with tensioning straps
Workshop hoist
Auxiliary plugs
Puller

Removal

  1. General notes:
    • If necessary, use Special Tool 24-003 when removing coolant hoses and vent hoses.
  1. Standard preparatory measures:
    • Make a note of the radio keycode.
    • Make a note of the pre-programmed radio stations.
    • Cut the cable ties and install new during installation, if necessary.
  1. CAUTION:
    CAUTION:Risk of scalding when the engine is hot. Failure to follow these instructions may result in personal injury.
    Open the coolant expansion tank.
  1. Disconnect the battery ground cable.

  1. Remove the battery.

  1. Remove the battery box.
    • Remove the bolts.

  1. NOTE:
    NOTE:Use an Allen key to stop the piston rod turning.
    Loosen the nuts on the two suspension struts five turns each.

  1. WARNING:
    WARNING:Risk of scalding when the engine is hot. Failure to follow this instruction may result in personnel injury.
    NOTE:
    NOTE:Tighten the drain plug when draining is completed.
    Drain off the coolant.
    • Unscrew the drain plug.

  1. Remove the air intake pipe.
    1. From the inlet manifold (clamp).
    1. Unclip the air intake pipe.
    1. Pull it out of the air cleaner housing (push fit).
    1. Detach the resonator hose (clamp).

  1. Detach the upper coolant hose.

  1. Detach the hoses.
    1. Vent hose
    1. Heater coolant hoses

  1. Detach the radiator vent hose.

  1. Disconnect the electrical connectors.
    1. Plug of injection pump wiring loom.
    1. Glow plug wiring.
    1. Plug of the temperature gauge sender unit.
    1. Plug of the engine coolant temperature sensor (ECT sensor).
    1. Fuel cut-off solenoid.
    1. Detach the brake servo vacuum line.

  1. Disconnect the oil pressure switch and diesel fuel heater electrical connectors.

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

  1. Disconnect the fuel return pipe.

  1. Disconnect the fuel feed pipe.

  1. Detach the transaxle ground lead.

  1. Detach the hydraulic pipe of the clutch operating mechanism.
    • Lift the clip and pull off the hydraulic pipe.
    • Plug the openings.

  1. Detach the power steering pressure pipe bracket and shield.
    • Remove the bolts.

  1. NOTE:
    NOTE:Collect the power steering fluid.
    Detach the power steering hose and pressure pipe.
    • Plug the openings.

  1. Remove the front engine mounting auxiliary bracket.

  1. Secure the top of the air conditioning condenser using cable ties.
  1. Raise and support the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.
  1. Remove the engine undershield.

  1. Remove the auxiliary drive shield.
    • Remove the bolt.
    • Remove the clip.

  1. Detach the lower coolant hose.

  1. Disconnect the air conditioning electrical connector.
    • Cut the two cable ties.

  1. Disconnect the air conditioning diode.
  1. Detach the coolant hose from the engine block.

  1. Disconnect the electrical connectors at the lower left-hand side of the radiator.

  1. NOTE:
    NOTE:Do not remove the air conditioning condenser.
    Detach the air conditioning condenser.
    • Remove the bolts.

  1. Remove the radiator (two bolts on each side, right-hand side shown).
    • Carefully withdraw the radiator, radiator crossmember and fan plate with the fan from below.

  1. Remove the auxiliary drive belt.
    1. Loosen the adjuster pulley bolt.
    1. Turn the adjuster bolt clockwise to de-tension the drive belt.

  1. NOTE:
    NOTE:Secure the air conditioning compressor to the front valance.
    Detach the air conditioning compressor.
    • Remove the bolts.

  1. Disconnect the starter motor.

  1. Disconnect the reversing lamp switch.

  1. Disconnect the generator electrical connectors.
  1. Detach the wiring harness from the transaxle.
    • Detach two clips.

  1. Detach the shift rod and gearshift stabiliser and tie up.
    1. Shift rod
    1. Stabiliser - gearshift

  1. Detach the speedometer drive cable.

  1. CAUTION:
    CAUTION:The inner joint should not be bent more than 18 degrees, and the outer joint should not be bent at more than 45 degrees.
    NOTE:
    NOTE:Fluid may escape. Seal the opening with an auxiliary plug.
    Using the Special Tool 16-089, disconnect the left-hand front halfshaft out of the transaxle.
    • Move the halfshaft forward and tie it up.

  1. Detach the rear exhaust pipe from the intermediate pipe.
    • Remove the gasket.

  1. Remove the exhaust downpipe and intermediate pipe.
    • Remove the downpipe exhaust manifold nuts.

  1. Detach the left and right-hand lower suspension arms (left-hand side shown). Protect the ball joint gaiters from damage by wrapping a thick cloth around them.

  1. CAUTION:
    CAUTION:The inner joint should not bent at more than 18 degrees, and the outer joint should not be bent at more than 45 degrees.
    CAUTION:
    CAUTION:After freeing the halfshaft, immediately secure the differential, using suitable plugs, to stop it from turning.
    Remove the right-hand front halfshaft from the transaxle.
    • Using the Special Tool disconnect the right-hand halfshaft from the transaxle.

  1. Remove the engine roll restrictor.
  1. NOTE:
    NOTE:Make sure that the assemblies are secure. Secure the engine on the assembly table with the tensioning straps.
    Preparations for removing the engine and transaxle assembly.
    • Position an assembly table with wooden blocks under the engine and transaxle assembly.
    • Lower the vehicle until the engine and transaxle assembly rests on the wooden blocks.

  1. Detach the rear engine mounting.
    • Remove the nuts.
    • Remove the transaxle breather.

  1. Remove the front engine mounting.
  1. Raise and support the vehicle slowly until the engine and transaxle are clear of the vehicle.

  1. Detach the engine from the manual transaxle.
    • Attach the engine lifting bracket.
  1. Lift the engine, together with the transaxle, using the workshop hoist.

  1. Remove the resonator.

  1. Remove the starter motor.

  1. Unscrew the front flange bolts.

  1. Unscrew the rear flange bolts.
  1. Detach the transaxle from the engine and remove it.
    • Remove the adaptor plate.

In-vehicle Repair|Disassembly > < Valve Seals