B1BG05K1 - 206 EW10J4 ENGINE

REMOVAL - REFITTING POWER UNIT

1 - SPECIAL TOOLS

[1] Cross beam (-).0102-D .

[2] Lifting chain (-).0102-M .

[3] Lever for uncoupling pivot ball joints (-).0622 .

[4] Final drive output oil seal fitting drifts (-).0317-T / (-).0317-U .

[5] Pipe with adapter for valve SHRADER (-).0141-T1 .

[6] Tool for unclipping 10 dia. ball joints (-).0216-G1 .

[7] Tool for unclipping 13 dia. ball joints (-).0216-G2 .

2 - REMOVAL

Drain :

• THE COOLING SYSTEM
• the gearbox
• the engine (if necessary)

Remove the drive shafts .

Remove the torque reaction link (1) .

Unclamp and move aside the power steering pipes attached to the engine .

Uncouple :

• the gearbox control rods (2) ; using tools [6] and [7]
• the exhaust pipe from the manifold

REMOVE THE ANCILLARY DRIVE BELT .

AIR CONDITIONING

Disconnect the compressor connector .

Remove the securing bolts (3) .

Without disconnecting the hoses, move aside and clamp the air conditioning compressor .

WARNING : take care not to bend the refrigerant pipes (risk of damage) .

ALL MODELS

Disconnect the connector (4) .

Unclamp the harness (5) .

Remove the clutch cable .

Remove the radiator bottom hose collar .

Remove the air cleaner and the air intake pipe .

Remove :

• the collar (6)
• the cover (7)
• the radiator

Move aside the power steering pump without opening the circuit .

Remove the bolt (8) .

Unclip the power steering pipe (9) .

Lower the fuel pressure by connecting the end of the tool [5] to the valve SHRADER (10); catch the fuel in a receptacle .

Disconnect, unclip and move aside :

• the pipe (12)
• the fuel supply pipe (11)
• the harness (13)

Remove the inlet manifold .

Move aside : The injection ECU .

Remove :

• the battery

Disconnect :

• the cables supplying the engine fuse box
• oxygen sensor
• the heater matrix pipes
• the expansion chamber pipes
• the earth lead

Remove : Ancillary drive belt tensioner roller .

Remove :

• the 2 securing bolts (14)
• the attached cables

Unscrew the bolts (15) without removing them .

Remove the alternator .

Remove the oil pressure switch (16) .

Position the lifting tool [1]-[2] on the engine sling hook .

Remove :

• the bolts (17)
• the connecting plate (18)
• the mounting (20)
• nut (21)

Remove :

• nut (22)
• the bolts (23)
• the bracket (24)
• the engine ; from above

3 - REFITTING

Fit :

• nut (21)
• the mounting (20)
• the connecting plate (18)
• the bolts (17)

Tighten :

• the nut (21) to 4,5 da.Nm
• the bolts (17) to 2,15 da.Nm

Fit :

• the bracket (24)
• the bolts (23)
• nut (22)

Tighten :

• the bolts (23) to 2,7 da.Nm
• the nut (22) to 6,5 da.Nm

Fit :

• the drive shafts
• the torque reaction link (3)

Tighten :

• the bolts (5) to 1,35 da.Nm
• the bolt (2) to 8,5 da.Nm
• the bolt (1) to 4,5 da.Nm
• the drive shaft nuts to 32,5 da.Nm.

Fit : The exhaust pipe .

Refit the pump respecting the order of assembly of the components .

Tighten in the order :

• the bolt (38) to 2,5 da.Nm
• the bolt (39) to 2,5 da.Nm + Loctite
• the bolt (40) to 2,2 da.Nm

Refit the oil pressure switch (16) .

Tighten the oil pressure switch to 3 daN.m. .

Fit :

• alternator
• roller tensioner

Tighten in the order :

• the bolts (14) to 4,1 da.Nm
• the bolts (15) to 3,9 da.Nm
• the bolt securing the roller : 3,5 da.Nm

Fit : The inlet manifold .

Tighten :

• the bolts to 2 da.Nm
• the nuts to 2 da.Nm

Continue the fitting operations in the reverse order to removal .

Refill :

• the gearbox
• the engine (if necessary)

Tighten the wheels to 8,5 daN.m .

Tighten the drive shaft nuts to 32,5 m.daN .

FILL AND BLEED THE COOLING SYSTEM .

Initialise the various ECUs .