B1BG0TK1 - 206 DW8 ENGINE

REMOVAL - REFITTING POWER UNIT

1 - SPECIAL TOOLS

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

[2] Lifting hooks, Reference (-).0102-J .

[3] Flywheel stop, Reference (-).0188-F .

[4] Forks for removing gearbox control rods, Reference (-).0102-G1 , (-).0102-G2 .

[5] Final drive output oil seal fitting drifts, Reference - (-).0317-T , 0317-U .

[6] Bonnet stay, Reference (-).0347-C .

2 - REMOVAL

The power unit is removed from above .

Place the bonnet in the vertical position Using the tool [6] .

Remove :

• the style cover (1)
• the air filter and its connections (2)
• the battery and its tray (3)
• the pre-heater unit (4)
• the 2 bolts (5)
• relay unit (6)
• the air cleaner bracket
• battery tray bracket

Disconnect and move aside :

• the fuel pipes (7)
• the ECU

Disconnect :

• the cables (8)-(9)

Disconnect and move aside :

• the pipe (10) (at (A))
• the pipe (11) (at (B))
• the pipe (12) (at (C))

Remove the hose (13) .

Remove the front wheels .

Drain :

• the gearbox
• THE COOLING SYSTEM

Remove :

• the mud shields
• the protective shield under the engine
• the drive shafts

Disconnect the connector (14), Front left wing inner panel .

POWER STEERING

Unclamp and move aside the power steering pipes attached to the engine (15) .

ALL MODELS

Remove the closing plate (16) .

Fit the tool [3] .

Uncouple the front exhaust pipe (Manifold side) .

Remove the torque reaction link (17) .

AIR CONDITIONING

Without opening the refrigerant fluid circuit, move aside the refrigeration compressor (18) .

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

ALL MODELS

Remove : The front panel .

POWER STEERING

Move aside the power steering pump without opening the circuit .

ALL MODELS

Disconnect and move aside :

• the heater matrix hoses (at the bulkhead)
• the brake servo vacuum pipe

Move aside the expansion chamber (19) and its unions .

Move aside :

• the accelerator cable

Move aside : Clutch cable .

RIGHT HAND DRIVE

Move aside the clutch slave cylinder (20) without opening the circuit .

ALL MODELS

Uncouple the gearbox control rods (Using the tool [4]) .

AIR CONDITIONING

Protect the condensor using stiff cardboard .

ALL MODELS

Remove :

• the ancillary drive belt
• the alternator
• the crankshaft pulley

Position the cross beam [1] with its hooks [2] on the sling eyes (21) and (22) then place it under tension .

Remove :

• the 3 bolts (23)
• the nut (24)
• the right-hand engine mounting (25)
• the nut (26)
• the 2 bolts (27)
• the flexible shim (28)
• the 2 bolts securing the bracket (29)
• the bracket (29)

Disconnect, unclip and separate the harnesses, pipes and cables connected to the gearbox or engine .

Retrieve the spacer (30) .

3 - REFITTING

Proceed in the reverse order to removal .

Always renew :

• the Nyloc nuts
• the final drive output oil seals, using drifts [5]

IMPERATIVE : fill the space between the oil seal lips with grease .

Position the spacer (30) on the gearbox shaft then coat it with PCAS SPAGRAH grease .

AIR CONDITIONING

Refit the compressor in the order of assembly shown above .

WARNING : the anti-rotation nut (31) secures the compressor at its upper rear end .

Firstly tighten the bolts on the crankshaft pulley side to 4.2 da.Nm then the bolts on the oil filter side to 3.9 da.Nm .

ALL MODELS

4 - TIGHTENING TORQUES

(23) Right engine mounting fastener : 4.5 da.Nm .

(24) Right-hand engine mounting fastener to flexible mounting : 4.5 da.Nm .

(32) Fastener for flexible mounting : 4 da.Nm .

(26) Gearbox mounting fixing to left side flexible block : 6.5 da.Nm .

(33) The shaft : 5 da.Nm .

(27) Flexible mounting to bracket fastening : 6 da.Nm .

(34) Flexible mount bracket to body : 2.7 da.Nm .

(35) Torque reaction rod fastener : 5 da.Nm .

(36) Rod to torque reaction link flexible mounting fastener : 3.5 da.Nm .

(37) Torque reaction link flexible mounting fastener : 4.5 da.Nm .

5 - REFITTING (CONTINUED)

Strictly follow the fastening and routes of the various harnesses and pipes .

Top up the gearbox oil .

FILL AND BLEED THE COOLING SYSTEM .

Initialise the various ECUs .