Contents: Removal ⬇ Installation ⬇
Removal
1. Place the vehicle on a two-post lift.
Caution: During this operation, secure the vehicle with a belt to avoid instability.
2. Remove the carpet under the left seat and the battery cover 1 (figure 2.3).
Figure 2.3. Remove the mat under the left seat and battery cover 1.
3. Disconnect the battery.
4. Remove the front wheels, engine sump, power wires, and ground wire from the body.
5. Set the power wires aside.
6. Drain the cooling system fluid through the lower radiator hose and drain the oil from the gearbox and engine if necessary.
Right side of the car
7. Remove the brake caliper and attach it to the suspension spring, ABS sensor, unscrew the lower ball joint nut (use a socket wrench with X = 22 mm if necessary to lock the ball joint), unscrew both bolts securing the gearbox flange to the bracket, remove the tie rod end using the T.Av. 476 tool and two shock absorber supports.
8. Disconnect the axle shaft.
9. Remove the hub together with the axle shaft.
Left side of the car
10. Remove the brake caliper and attach it to the suspension spring, ABS sensor, unscrew the lower ball joint nut (use a socket wrench with X = 22 mm if necessary to lock the ball joint), remove the tie rod end using the T.Av. 476 tool, the half-shaft protection supports and the two shock absorber supports.
11. Disconnect the axle shaft.
12. Remove the hub together with the axle shaft.
13. Remove the number plate, indicator lights and radiator grille (figure 2.4).
Figure 2.4. Remove the radiator grille.
14. Unscrew the 2 headlight mounting bolts (figure 2.5).
15. Disconnect the wiring connectors from the headlight.
Figure 2.5. Unscrew the bolts 2 securing the headlight.
16. Remove the headlight by removing the clips 3 (figure 2.6).
Figure 2.6. Remove the headlight by removing the fasteners 3.
17. Remove the bumper (figure 2.7a, b).
Figure 2.7a. Remove the bumper.
Figure 2.76. Remove the bumper.
18. Remove the power steering fluid reservoir.
19. Remove the hood locking mechanism 4, disconnect the hood release cable (figure 2.8).
Figure 2.8. Remove the hood locking mechanism 4.
20. Remove the upper and lower radiator supports, radiator grille, radiator air ducts, air resonator.
21. Disconnect the wiring connectors from the fan and the wiring connector from the pressure sensor.
22. Disconnect the air conditioning system pipes from the compressor and condenser.
23. Disconnect the wiring connector from the fuel shut-off sensor 5 (figure 2.9).
Figure 2.9. Disconnect the wiring connector from the fuel shut-off sensor 5.
24. Remove the radiator, expansion tank and engine control unit protective plate.
25. Disconnect the wiring connector from the engine control unit.
26. Remove all fuse holders.
27. Disconnect the ground wire on the left side.
28. Remove the heater radiator pipes using Mot. 1448.
Figure 2.10. Disconnect the wiring connector from the engine control unit.
29. Disconnect vacuum pipe 6 from the brake booster (figure 2.11).
Figure 2.11. Disconnect vacuum pipe 6 from the brake booster.
30. Disconnect the fuel intake line.
31. Remove the clutch slave cylinder retainer, the 7 pipe retainer and the gear shift and selection cables (figure 2.12).
Figure 2.12. Remove clamp 7 of the clutch hydraulic drive line.
32. Disconnect the wiring connector 8 (figure 2.13).
Figure 2.13. Disconnect wiring connector 8.
33. Remove the heater.
34. Remove the air filter.
35. Disconnect the gasoline vapor recovery pipe.
35. Disconnect the wiring connector from the throttle body.
36. Unscrew the two bolts 9 securing the throttle body and remove it (figure 2.14).
Figure 2.14. Unscrew the two bolts 9 securing the throttle body and remove it.
37. Drain the fluid from the power steering reservoir.
38. Disconnect the power steering pipes from the steering gear.
39. Disconnect the oxygen sensor 10 (figure 2.15). Unscrew bolts 11 securing the catalytic converter bracket and remove the catalytic converter.
Figure 2.15. Disconnect oxygen sensor 10. Unscrew bolts 11 securing the catalytic converter bracket and remove the catalytic converter.
40. Disconnect the lower cross member and engine mount arms.
41. Fit the Mot. 1390 engine and gearbox support device under the engine.
42. The rollers should be located under the grey areas 12 and as close to the engine as possible (figure 2.16).
Figure 2.16. The rollers should be located under the grey areas 12 and as close to the engine as possible.
43. Remove the right engine mount support (figure 2.17).
Caution: Make sure the engine is mounted on the support device before completely loosening the bolts.
44. Unscrew nut 13 and hit it with a copper hammer (figure 2.18). Remove the rubber cushion and gearbox support.
Figure 2.17. Remove the right engine mount support.
Figure 2.18. Unscrew nut 13.
Installation
45. Installation is carried out in the reverse order of removal.
Tightening torques
- Brake caliper bolt -35 Nm.
- Shock absorber mounting bolt -180 Nm.
- Steering rod ball joint mounting nut - 37 Nm.
- Gearbox suspension nut -62 Nm.
- Lower ball joint nut -110 Nm.
- Engine pendulum mount bolt - 105 Nm.
- Upper rod bolt of engine pendulum mount - 105 Nm.
- Axle shaft protection bolt - 44 Nm.
- Wheel mounting bolt - 140 Nm.
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