Dismantling
1. Disconnect "negative" battery terminal.
2. Disconnect the generator.
3. Remove the outer wheel arch panel.
REPAIR WORKS, Wheel arch outer panel.
4. Remove the lower motor protection shield.
EXTERIOR PARTS, REPAIR WORKS, Engine protection - front.
5. Remove the front bumper assembly.
EXTERIOR PARTS, REPAIR WORKS, Front bumper assembly.
6. Remove a beam of a forward bumper.
EXTERIOR PARTS, REPAIR WORKS, Front bumper assembly.
7. Remove the radiator.
COOLING SYSTEM: Td6, REPAIR WORKS, Radiator.
8. Left side: Remove the radiator expansion tank.
COOLING SYSTEM: Td6, REPAIR WORKS, Radiator.
9. Drain the A/C system and collect the refrigerant.
AIR CONDITIONING SYSTEM, AIR CONDITIONER DRAINAGE, REFRIGERANT RECOVERY AND CHARGING, Air Conditioner Emptying - Refrigerant Recovery and Charging.
NOTE: The water separator must be replaced if the following occurs: There is dirt in the air conditioning system (compressor stuck). The tightness of the system is broken, and the refrigerant enters the atmosphere. As a result of the repair, the air conditioning system remained open for more than 24 hours.
10. Remove the air conditioning lines from the side member.
11. Right side: Remove the automatic transmission cooler.
AUTOMATIC TRANSMISSION - GM 5L40-E, REPAIR WORK, Automatic transmission cooler.
12. Diesel vehicles: Loosen fasteners and remove intercooler lines.
13. For vehicles with a diesel engine: Remove the diesel heater assembly.
14. For vehicles with a 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 WORKS, Bottom trim - windshield.
17. Remove the vacuum booster.
BRAKING SYSTEM, REPAIR WORKS, Pneumatic booster assembly.
18. Remove the drain tube from the air intake box.
19. Remove the accelerator pedal.
20. Remove the front fender.
EXTERIOR PARTS, REPAIR WORKS, Front fender.
21. Remove the front wheel arch liner.
EXTERIOR PARTS, REPAIR WORKS, Fender liner - front wheel arch.
22. Remove the power steering lines to gain access to the side member.
23. Left side: Remove the windshield washer reservoir.
24. Remove the generator.
SYSTEM OF STARTING THE ENGINE AND CHARGING THE BATTERY, REPAIR WORKS, Generator - engine Td6.
25. Remove the ABS pressure regulator.
BRAKE SYSTEM, REPAIR WORKS, ABS pressure regulator unit.
26. Remove the fuel lines from the side member.
27. Left side: Remove the fuel filter.
FUEL SUPPLY OF Td6 ENGINE, REPAIR WORK, Fuel filter.
28. Left side: Remove the battery tray.
SYSTEM OF STARTING THE ENGINE AND CHARGING THE BATTERY, REPAIR WORKS, Support tray - storage battery.
29. Remove the air suspension strut assembly.
FRONT SUSPENSION, REPAIRS, Air Spring Assembly.
30. Right side: Remove the air suspension reservoir.
FRONT SUSPENSION, REPAIR WORKS, Receiver.
31. Remove the brake and fuel lines.
32. Disconnect the wiring harnesses and take them aside.
33. Remove the sealing mastic from the lower bulkhead of the body.
34. Remove the heat shield from the tunnel.
35. Remove the steering column assembly.
STEERING, REPAIR WORKS, Steering column assembly - inner and outer parts.
36. Remove the control panel support cross member.
CAR INTERIOR PARTS, REPAIR WORKS, Control panel - support.
37. Remove the front carpet to access the welds.
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. Restore the tightness of the bottom panel of the bulkhead.
2. Lay the front carpet in place.
3. Replace the control panel support cross member.
CAR INTERIOR PARTS, REPAIR WORKS, Control panel - support.
4. Install the steering column assembly.
5. Install the tunnel heat shield.
6. Install and secure wiring harnesses.
7. Install brake and fuel lines.
8. Install the air suspension strut assembly.
FRONT SUSPENSION, REPAIRS, Air Spring Assembly.
9. Right side: Install the air suspension reservoir.
FRONT SUSPENSION, REPAIR WORKS, Receiver.
10. Left side: Install the fuel filter.
ENGINE FUEL SUPPLY Td6, Fuel filter, Fuel filter.
11. Left side: Replace the battery tray.
SYSTEM OF ENGINE START AND CHARGING OF AKB, REPAIR WORKS, Platform - rechargeable battery.
12. Attach the fuel lines to the side member.
13. Install the ABS pressure regulator.
BRAKE SYSTEM, REPAIR WORKS, ABS pressure regulator unit.
14. Install the vacuum brake booster.
BRAKING SYSTEM, REPAIR WORKS, Pneumatic booster assembly.
15. Reinstall the generator.
SYSTEM OF STARTING THE ENGINE AND CHARGING THE BATTERY, REPAIR WORKS, Generator - engine Td6.
16. Reinstall the front wheel arch liner.
EXTERIOR PARTS, REPAIR WORKS, Fender liner - front wheel arch.
17. Reinstall the front fender.
EXTERIOR PARTS, REPAIR WORKS, Front fender.
18. Reinstall the power steering lines.
19. Install the accelerator pedal.
20. Install the air intake box drain tube.
21. Establish the bottom overlay of a windscreen.
EXTERIOR PARTS, REPAIR WORKS, Lower trim windshield.
22. For vehicles with a diesel engine: Install the diesel heater assembly.
23. For vehicles with a diesel engine: Install the diesel heater fuel pump.
24. For vehicles with a diesel engine: Connect and secure the intercooler lines.
25. Right side: Install the automatic transmission cooler.
26. Fix lines of the conditioner on a side member.
27. Fill the A/C system.
AIR CONDITIONING SYSTEM, AIR CONDITIONER DRAINAGE, REFRIGERANT RECOVERY AND CHARGING, Air Conditioner Emptying - Refrigerant Recovery and Charging.
28. Left side: Reinstall the coolant expansion tank.
COOLING SYSTEM: Td6, REPAIR WORKS, Radiator.
29. Replace the air intake box.
HEATING AND VENTILATION, REPAIR WORKS, Air intake box.
30. Left side: Install the windshield washer reservoir.
31. Install the radiator.
COOLING SYSTEM: Td6, REPAIR WORKS, Radiator.
32. Reinstall the front bumper beam.
EXTERIOR PARTS, REPAIR WORKS, Front bumper assembly.
33. Reinstall the front bumper assembly.
EXTERIOR PARTS, REPAIR WORKS, Front bumper assembly.
34. Replace the lower engine shield.
EXTERIOR PARTS, REPAIR WORKS, Engine protection - front.
35. Connect the generator.
36. Attach "negative" terminal to the battery.
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