Dismantling
1. Disconnect "negative" battery terminal.
2. Disconnect all electronic units.
3. Remove the wheel (wheels).
4. Remove the lower motor protection shield.
EXTERIOR PARTS, REPAIR WORKS, Engine lower shield.
5. Remove the front bumper.
EXTERIOR PARTS, REPAIR WORKS, Front bumper assembly - for vehicles up to 2004 model year.
6. Remove a beam of a forward bumper.
7. Remove the radiator.
COOLING SYSTEM: MOD. K, KV6 engine, REPAIR WORK, Radiator assembly.
8. Remove the power steering fluid cooler.
STEERING, Steering Gear, Power Steering Fluid Cooler (for models with Td4 or K1.8 engine).
9. Remove the headlight.
LIGHTING, Headlight assembly - models up to 2004 model year, Headlight assembly - models up to 2004 model year.
10. Release the headlight wiring harness and move it aside.
11. Remove the mudguard of the engine compartment.
12. Remove the front wheel arch liner.
EXTERIOR PARTS, REPAIR WORKS, Front fender liner.
13. Remove the front fender.
EXTERIOR PARTS, REPAIR WORKS, Front fender.
14. Remove a back beam of a forward suspension bracket.
15. Remove the engine and transmission.
KV6 ENGINE - VERSION K, Left cylinder head camshafts, Engine and automatic transmission: up to May 2003.
16. Remove the front suspension strut.
FRONT SUSPENSION, REPAIR WORKS, Shock absorber.
17. Remove the rack and pinion with power steering.
STEERING, Steering gear, Steering gear.
18. Remove the control panel.
INTERIOR TRIM PARTS, REPAIRS, Control panel - for cars up to 2004 model year.
19. Left side: Remove the left bumper bracket.
20. Left side: Remove the air cleaner.
21. Left side: Remove the air tube.
22. Left side: Remove the electronic engine control unit (ECM).
23. Left side: Remove the engine compartment relay and fuse box.
24. Left side: Remove the battery tray.
SYSTEM OF STARTING THE ENGINE AND CHARGING THE BATTERY, REPAIR WORKS, Support tray - storage battery.
25. Left side: Remove the engine compartment relay and fuse box with its respective wiring harnesses.
26. Left side: Remove the left engine mount from the body.
27. Left side: On diesel models, remove the fuel filter.
DIESEL ENGINE FUEL SUPPLY, REPAIR WORKS, Fine fuel filter: up to May 2003.
28. Left side: Remove the left front brake pipe.
29. Right side: Remove the right bumper bracket.
30. Right side: Remove the windshield washer reservoir.
WIPERS AND WASHERS, REPAIR WORKS, Reservoir - washer.
31. Right side: Remove the expansion tank of the cooling system.
32. Right side: Remove the right engine mount from the body.
33. Right side: Remove the power steering fluid reservoir.
34. Right side: Remove the right front brake pipe.
35. Driver's side: Remove the passenger compartment relay and fuse box.
36. Remove the brake pedal assembly and brake servo.
37. Remove the clutch pedal assembly.
38. Release the cable harness from the sidewall and take it aside.
39. Remove an overlay of a threshold of an aperture of a forward door. Loosen the front floor mat and slide it to the side.
40. Remove insulating slips from a partition of a motor compartment.
Repair work
1. Remove damaged panels, prepare joint edges and install new panels in accordance with the Body Panel Repair Code. Punch or drill holes in the panel to be installed for the cork weld as shown.
Assembly
1. Install the insulating pads on the front and rear sides of the bulkhead of the engine compartment.
2. Replace the front carpet and install the front door sill trim.
3. Attach the wiring harness to the side of the engine compartment.
4. Driver's side: Install the clutch pedal assembly.
5. Install the brake pedal assembly and brake servo.
6. Establish the block of the relay and safety locks of inside of the car.
7. Left side: Install the left front brake pipe. Bleed the brake system.
BRAKING SYSTEM, ADJUSTMENTS, Bleeding of air from the brake system.
8. Left side: On diesel models, install the fuel filter.
DIESEL ENGINE FUEL SUPPLY, REPAIR WORKS, Fine fuel filter: up to May 2003.
9. Left side: Install the left engine mount.
10. Left side: Install the engine compartment relay and fuse box with its respective wiring harnesses
11. Left side: Replace the battery tray. Don't join "negative" battery terminal.
SYSTEM OF STARTING THE ENGINE AND CHARGING THE BATTERY, REPAIR WORKS, Support tray - storage battery.
12. Left side: Install the engine compartment relay and fuse box.
13. Left side: Install the ECM (ECM).
14. Left side: Install the air tube.
15. Left side: Install the air filter.
16. Left side: Install the left bumper bracket.
17. Right side: Install the right front brake pipe. Bleed the brake system.
BRAKING SYSTEM, ADJUSTMENTS, Bleeding of air from the brake system.
18. Right side: Install the power steering fluid reservoir.
19. Right side: Install the right engine mount.
20. Right side: Reinstall the coolant expansion tank.
21. Right side: Install the windshield washer reservoir.
WIPERS AND WASHERS, REPAIR WORKS, Reservoir - washer.
22. Right side: Install the right bumper bracket.
23. Replace the control panel.
INTERIOR TRIM PARTS, REPAIRS, Control panel - for cars up to 2004 model year.
24. Install the power steering rack and pinion.
STEERING, Steering gear, Steering gear.
25. Install the front suspension strut.
FRONT SUSPENSION, REPAIR WORKS, Shock absorber.
26. Install the engine and gearbox.
KV6 ENGINE - VERSION K, Left cylinder head camshafts, Engine and automatic transmission: up to May 2003.
27. Establish a back beam of a forward suspension bracket.
28. Reinstall the front fender.
EXTERIOR PARTS, REPAIR WORKS, Front fender.
29. Reinstall the front wheel arch liner.
EXTERIOR PARTS, REPAIR WORKS, Front fender liner.
30. Install the engine compartment mudguard.
31. Install the headlight.
LIGHTING, Headlight assembly - models up to 2004 model year, Headlight assembly - models up to 2004 model year.
32. Attach the headlight wiring harness. Install the power steering fluid cooler.
STEERING, Steering Gear, Power Steering Fluid Cooler (for models with Td4 or K1.8 engine).
33. Install the radiator.
COOLING SYSTEM: MOD. K, KV6 engine, REPAIR WORK, Radiator assembly.
34. Establish a beam of a forward bumper.
35. Reinstall the front bumper.
EXTERIOR PARTS, REPAIR WORKS, Front bumper assembly - for vehicles up to 2004 model year.
36. Reinstall the lower engine shield.
EXTERIOR PARTS, REPAIR WORKS, Engine lower shield.
37. Replace the wheel (wheels) and tighten the nuts to a torque of 115 Nm.
38. Attach all electronic units.
39. Attach "negative" battery terminal.
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