ZEST BOLT Service Manual

ENGINE 1.3 QUADRAJET (90PS) 22 3A.1.2 ENGINE – MECHANICAL 3A.1.2.1 REMOVAL OF ENGINE FROM VEHICLE 1. Remove the Hood (Bonnet), for procedure refers. BODY GROUP. 2. Remove the Air Filter Assembly, for procedure refers air filter assembly – removal. 3. Disconnect the battery (Negative first). 4. Disconnect the Engine electrical harness connector. 5. Disconnect the ECU Connectors. 6. Disconnect the heater plug control unit. 7. Disconnect the starter electrical connections. 8. Recover the AC refrigerant using a AC Refrigerant recycler, drain the coolant. 9. Drain the Engine oil; refer ENGINE OIL DRAIN for procedure. 10. Drain the transaxle oil, by loosening the drain plug (1). 11. To remove the Exhaust front pipe loosen the bolt (1) and disconnect it at the rear end and pull it towards rear. 12. Remove the Wheels, and remove the drive shafts. For procedure refer DRIVE SHAFT removal and refitment. 13. Disconnect the Gear shifter cables; refer GEAR SHAFT ER MECHANISM for procedure. NOTE Make sure that before the right drive shaft is removed, the intermediate shaft mounting bracket is freed from engine case by removing the 3 mounting bolts (1). 14. Disconnect the Fuel return line and Fuel delivery line. 15. Disconnect the vacuum hose from Brake Booster. 16. Disconnect the HVAC/FATC heater pipes.