1) Remove bonnet 2) Remove front wheels 3) Remove battery 4) Remove plastic battery tray 5) Remove metal battery tray 6) Remove top of air cleaner -5 bolts & electric connection 7) Remove bottom of air cleaner including induction pipe - 2 of 6mm. bolts 8) Remove 2 inner wing covers - 4 bolts 2 of which have cable brackets attached to them
Subframe removal: 9) Remove exhaust front pipe,note there is no gasket on rear flange 10) Disconnect front lower ball joints 11) Remove 3 front engine mounting nuts & bolts 12) Disconnect steering u/j,note it is not master splined 13) Disconnect hydraulic hose from steering pump to rack 14) Disconnect hydraulic hose near steering u/j 15) Support engine 16) Remove rear engine mount 17) Disconnect track rod ends 18) Disconnect bracket at front of subframe holing aircon pipe - 1 bolt 19)Disconnect bracket holding bottom hose to front of subframe -2 bolts 20) Remove 4 subframe nuts 21) Remove subframe
22) Pull slave cylinder & pipe away 23) Disconnect drive shafts 24) Remove gearbox top mount 25) Disconnect gearchange cables - note their positions
26) Disconnect crank position sensor 27) Remove front gearbox mount - only 1 bolt left to remove since other 2 were removed when pulling slave cylinder away - take mount right off vehicle 28) Remove gear change cable bracket - 4 bolts 29) Remove 10mm. headed bolt at bottom of bell housing - screws into bell housing 30) Disconnect speedo sensor 31) Disconnect reverse switch 32) Remove 3 starter bolts
33) Remove bell housing bolts,the 2 bolts at bottom have 14mm. heads 34) Remove 2 of bolts securing flywheel plate 35) Remove gearbox
Derek Watts, February 2009
