Dismantling
1. Disconnect the negative terminal from the battery.
2. Disconnect the generator.
3. Remove the lower engine protection shield.
EXTERIOR PARTS, REPAIR WORK, Engine protection - front.
4. Remove the front bumper assembly.
EXTERIOR PARTS, REPAIR WORK, Front bumper assembly.
5. Remove the front bumper beam.
EXTERIOR PARTS, REPAIR WORK, Front bumper assembly.
6. Remove the radiator.
COOLING SYSTEM: Td6, REPAIR WORK, Radiator.
7. Left side: Remove the radiator expansion tank.
COOLING SYSTEM: Td6, REPAIR WORK, Radiator.
8. Drain the air conditioning system and collect the refrigerant.
AIR CONDITIONING SYSTEM, AIR CONDITIONER DRAINING, REFRIGERANT RECOVERY AND CHARGING, Air conditioner draining - refrigerant recovery and charging.
NOTE: The receiver/dryer separator should be replaced if the following occurs: There is dirt in the air conditioning system (the compressor jammed). The system is leaking and refrigerant is leaking into the atmosphere. As a result of the repair, the air conditioning system remained open for more than 24 hours.
9. Remove the air conditioning lines from the side member.
10. Remove the engine.
11. Right side: Remove the automatic transmission cooler.
AUTOMATIC TRANSMISSION - GM 5L40-E, REPAIR WORK, Automatic transmission cooler.
12. For diesel vehicles: Loosen and remove the intercooler pipes.
13. For diesel vehicles: Remove the diesel heater assembly.
14. For vehicles with diesel engine: Remove the diesel heater fuel pump.
15. Remove the air intake box.
HEATING AND VENTILATION, REPAIR WORKS, Air intake box.
16. Remove the lower windshield trim.
EXTERIOR PARTS, REPAIR WORK, Lower trim - windshield.
17. Remove the air intake box drain pipe.
18. Remove the accelerator pedal.
19. Remove the front wing.
EXTERIOR PARTS, REPAIR WORK, Front wing.
20. Remove the front wheel arch liner.
EXTERIOR PARTS, REPAIR WORK, Mudguard - front wheel arch.
21. Remove the power steering lines to gain access to the side member.
22. Left side: Remove the windshield washer reservoir.
23. Remove the generator.
ENGINE STARTING AND BATTERY CHARGING SYSTEM, REPAIR WORK, Generator - Td6 engine.
24. Remove the ABS pressure regulator.
BRAKE SYSTEM, REPAIR WORK, ABS pressure regulator unit.
25. Remove the vacuum booster.
BRAKE SYSTEM, REPAIR WORK, Pneumatic booster assembly.
26. Remove the fuel lines from the side member.
27. Left side: Remove the fuel filter.
FUEL SUPPLY SYSTEM OF THE Td6 ENGINE, REPAIR WORK, Fuel filter.
28. Left side: Remove the battery tray.
ENGINE STARTING AND BATTERY CHARGING SYSTEM, REPAIR WORK, Platform - battery.
29. Remove the air suspension strut assembly.
FRONT SUSPENSION, Anti-roll bar, Air spring assembly.
30. Right side: Remove the air suspension receiver.
FRONT SUSPENSION, REPAIR WORK, Receiver.
31. Remove the brake and fuel lines.
32. Disconnect the wire harnesses and move them to the side.
33. Remove the sealing mastic from the lower body bulkhead.
34. Remove the heat shield from the tunnel.
35. Remove the control panel cross member.
CAR INTERIOR PARTS, REPAIR WORK, Control panel - support.
36. Remove the front carpet to access the welds.
Repair works
1. Remove damaged panels, prepare joint edges and install new panels in accordance with the Body Panel Repair Guidelines. Punch or drill holes in the panel to be installed for the plug weld as shown in the figure. The panel shaded in the figure must also be removed during this procedure.
Assembly
1. Restore the tightness of the lower panel of the body partition.
2. Place the front carpet back in place.
3. Reinstall the control panel cross member.
CAR INTERIOR PARTS, REPAIR WORK, Control panel - support.
4. Install the tunnel heat shield.
5. Route the wire harnesses and secure them.
6. Install the brake and fuel lines.
7. Install the air suspension strut assembly.
FRONT SUSPENSION, REPAIR WORK, Air spring assembly.
8. Right side: Install the air suspension receiver in place.
FRONT SUSPENSION, REPAIR WORK, Receiver.
9. Left side: Install the fuel filter.
FUEL SUPPLY SYSTEM OF THE Td6 ENGINE, REPAIR WORK, Fuel filter.
10. Left side: Reinstall the battery tray.
ENGINE STARTING AND BATTERY CHARGING SYSTEM, REPAIR WORK, Platform - battery.
11. Secure the fuel lines to the side member.
12. Install the ABS pressure regulator.
BRAKE SYSTEM, REPAIR WORK, ABS pressure regulator unit.
13. Install the brake booster.
BRAKE SYSTEM, REPAIR WORK, Pneumatic booster assembly.
14. Reinstall the generator.
ENGINE STARTING AND BATTERY CHARGING SYSTEM, REPAIR WORK, Generator - Td6 engine.
15. Reinstall the front wheel arch liner.
EXTERIOR PARTS, REPAIR WORK, Mudguard - front wheel arch.
16. Install the front fender in place.
EXTERIOR PARTS, REPAIR WORK, Front wing.
17. Reinstall the power steering lines.
18. Install the air intake box drain pipe.
19. Install the lower windshield trim.
EXTERIOR PARTS, REPAIR WORK, Lower trim - windshield.
20. Install the accelerator pedal.
21. Install the engine.
22. For diesel vehicles: Reinstall the diesel heater assembly.
23. For diesel vehicles: Install the diesel heater fuel pump.
24. For diesel vehicles: Connect and secure the intercooler pipes.
25. Secure the air conditioning lines to the side member.
26. Right side: Reinstall the automatic transmission cooler.
27. Left side: Install the coolant expansion tank in place.
COOLING SYSTEM: Td6, REPAIR WORK, Radiator.
28. Install the air intake box in place.
HEATING AND VENTILATION, REPAIR WORKS, Air intake box.
29. Left side: Install the windshield washer reservoir.
30. Install the radiator.
COOLING SYSTEM: Td6, REPAIR WORK, Radiator.
31. Install the front bumper beam in place.
EXTERIOR PARTS, REPAIR WORK, Front bumper assembly.
32. Reinstall the front bumper assembly.
EXTERIOR PARTS, REPAIR WORK, Front bumper assembly.
33. Reinstall the lower engine protection shield.
EXTERIOR PARTS, REPAIR WORK, Engine protection - front.
34. Fill the air conditioning system.
AIR CONDITIONING SYSTEM, AIR CONDITIONER DRAINING, REFRIGERANT RECOVERY AND CHARGING, Air conditioner draining - refrigerant recovery and refilling.
35. Connect the generator.
36. Connect the negative terminal to the battery.
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