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2.2L Turbo Diesel

WARNING: This page is about a different variant/trim than selected.
Fig 1: Air Cleaner Assembly
GC0022003Courtesy of DAIMLERCHRYSLER CORP.
1 - DUCT
2 - MASS AIR FLOW SENSOR
3 - AIR CLEANER ASSEMBLY
4 - BRACKET
  1. Disconnect battery negative cable.
  2. Remove air cleaner assembly (3). See Fig 1.
  3. Remove Power Distribution Center (PDC) from bracket. Remove Air Cleaner/PDC mounting bracket.
    Fig 2: Gear Shift Cables and Bracket at Transaxle
    GC0022005Courtesy of DAIMLERCHRYSLER CORP.
    1 - TRANSAXLE
    2 - GEAR SHIFT CABLE BRACKET
    3 - BOLT (3)
    4 - CABLE ASSEMBLY
    5 -CLIPS (2)
  4. Disconnect gearshift cables (4). See Fig 2. from shift mechanism and bracket. Position cables out of way.
  5. Remove gearshift cable bracket (2). See Fig 2.
    Fig 3: Power Steering Reservoir
    GC0022006Courtesy of DAIMLERCHRYSLER CORP.
    1 - RESERVOIR
    2 - BOLT
  6. Remove power steering reservoir (1) mounting bolts (2). See Fig 3.
    Fig 4: VSS and Back-Up Lamp Switches
    GC0022007Courtesy of DAIMLERCHRYSLER CORP.
    1 - BACK-UP LAMP SWITCH
    2 - VEHICLE SPEED SENSOR (VSS)
  7. Disconnect back-up lamp switch (1) connector. See Fig 4.
  8. Disconnect vehicle speed sensor (2) connector. See Fig 4.
    Fig 5: Disconnecting Clutch Hydraulic Quick Connect Fittiing Using Tool 6638A
    GC0020073Courtesy of DAIMLERCHRYSLER CORP.
    1 - QUICK CONNECT FITTING
    2 - DISCONNECT TOOL 6638 A
  9. Disconnect clutch master cylinder hydraulic tube from clutch slave cylinder using Disconnect Tool 6638 A (2). See Fig 5.
    Fig 6: Transaxle Fluid Drain and Fill Plugs
    GC0022014Courtesy of DAIMLERCHRYSLER CORP.
    1 - FILL PLUG
    2 - DRAIN PLUG
    3 - RIGHT AXLE SEAL
  10. Remove transaxle upper bellhousing-to-block bolts.
  11. Raise vehicle on hoist.
  12. Remove transaxle drain plug (2) and drain into suitable container. See Fig 6.
    Fig 7: Halfshaft And Intermediate Shaft (2.2L TD Shown - 2.4L Turbo Similar)
    GC0019626Courtesy of DAIMLERCHRYSLER CORP.
    1 - HALFSHAFT (LH)
    2 - TRANSAXLE
    3 - INTERMEDIATE SHAFT
    4 - BOLT (3)
    5 - HALFSHAFT (RH)
  13. Remove halfshafts (1, 5). See Fig 7.
  14. Remove three intermediate shaft bearing-to-retainer bolts. Remove intermediate shaft/bearing assembly.
    Fig 8: Intercooler Inlet Hose Fasteners
    GC0022009Courtesy of DAIMLERCHRYSLER CORP.
    1 - INTERCOOLER INLET HOSE
    2 - BOLTS (2)
    3 - STRUCTURAL COLLAR
  15. Remove two intercooler connector pipe-to-engine oil pan bolts (2) and position aside to access and remove oil pan-to-bellhousing bolt. See Fig 8.
    Fig 9: Upper Mount-to-Bracket
    GC0022010Courtesy of DAIMLERCHRYSLER CORP.
    1 - BOLT (2)
    2 - MOUNT
    3 - BRACKET
  16. Position screw jack and wood block to engine oil pan.
  17. Obtain access to engine compartment. Remove two transaxle upper mount-to-bracket bolts (1). See Fig 9.
    Fig 10: Transaxle Upper Mount Bracket
    GC0022011Courtesy of DAIMLERCHRYSLER CORP.
    1 - TRANSAXLE
    2 - BRACKET
    3 - BOLT
  18. Lower engine/transaxle assembly on screw jack.
  19. Remove transaxle upper mount bracket (2). See Fig 10.
    Fig 11: Starter Bolt and Ground Cable
    GC0022012Courtesy of DAIMLERCHRYSLER CORP.
    1 - GROUND CABLE
    2 - BOLT
    3 - STARTER MOTOR
  20. Position transmission jack to transaxle. Secure transaxle to jack.
  21. Remove starter lower bolt (2) with ground cable. See Fig 11.
  22. Remove remaining bellhousing-to-block bolts.
  23. Lower transaxle assembly from engine/vehicle.
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