B1BG11K1 - 206 DW10TD ENGINE

REMOVAL - REFITTING POWER UNIT

1 - SPECIAL TOOLS

[1] Load balancer Type NAUDER .

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

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

[4] Tool for unclipping the ball joints (-).0317-AC .

[5] Pulley extractor (-).0188-P .

[6] Set of plugs (-).0188-T .

[7] Socket for the removal of the gearbox shaft (-).0317-AB .

2 - REMOVAL

Disconnect the battery .

POSITION THE RODS FOR RETAINING THE SUSPENSION SPRINGS .

The power unit is removed from above .

Remove the shields under the power train .

Drain :

• the cooling system
• the gearbox
• the engine (if necessary)

Remove :

• the wheels
• the mud shields
• the drive shafts
• THE ANCILLARY DRIVE BELT

IMPERATIVE : remove the exhaust pipe to avoid damaging the flexible hose; this cannot withstand the torsion, traction or bending tensions caused by the removal of one of the power train supports .

AIR CONDITIONING

RemoveThe eccentric roller of the ancillaries drive belt .

ALL MODELS

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

Unclip the power steering pipe (2) .

Remove :

• the clutch housing closing plate

Lock the flywheel with the stop [3] .

Remove :

• the ancillary drive pulley (using the tool [5])

Remove : The torque reaction link (3) .

Remove : The style cover (4) .

Move aside : The assembly (5) .

Disconnect and move aside the harnesses and cables attached to the assembly (5) .

Remove the battery .

Disconnect, unclip and move aside the harnesses attached to the battery tray .

Remove :

• the battery container (6)
• the assembly support (5)
• the expansion chamber (7)
• the radiator

Protect the condenser with a panel of strong cardboard .

Mark the position of the pipes (8) on the solenoid valves (9) .

Remove : The solenoid valves bracket .

Move aside The brake servo vacuum pipe (10) .

Move aside :

• the ECU (11) and its support
• the fuel pipes (12)

Plug the holes using tool [6] .

Move aside the harness (13) .

Remove :

• the fuse box cover (14)
• the air duct (15)

Disconnect, unclamp and remove the harnesses from the fuse box .

Move aside The clutch control .

Move aside :

• the heater matrix hoses (16)
• the earth cable (chassis leg)
• the heater assembly (17)

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

WARNING : pressure must be applied to the tools to unclip the ball joints; they must not be used as levers as this may bend the connecting rods .

Without disconnecting the hoses, move aside and clamp the power steering pump .

Remove the alternator (19) .

Remove the assembly (20) .

Unclamp the air conditioning pipes (Front right chassis leg) .

AIR CONDITIONING

Move aside the buffer tank (21) without disconnecting the pipes .

ALL MODELS

Remove the assembly (22) .

Fit the tool [1] .

Remove :

• the connecting plate (23)
• the stop (24)
• the right-hand engine mounting (25)

Remove :

• the fasteners (26)
• the battery tray support (27)
• the gearbox shaft nut (28) and its washer
• the mounting bolts (29)
• the gearbox flexible mounting (30)
• the bolts (31)
• the bracket (32)
• the spacer (33)
• the shaft (34) (using the tool [7])
• the bolts (35)
• the bracket (36)

Remove the power unit from above .

3 - REFITTING

Always renew :

• the Nyloc nuts
• the exhaust clip

Use the drifts [2] to fit the final drive oil seals, having greased the space between the seal lips .

Position the power train .

Refit the right-hand engine mounting (25) .

Tighten :

• the bolts (37) to 4,5 da.Nm
• the bolt (38) to 4,5 da.Nm

Fit :

• the stop (24); tightening torque 3,2 da.Nm
• the connecting plate (23); tightening torque 2,15 da.Nm

Fit :

• the bracket (36)
• the bolts (35); tightening torque 6 da.Nm
• the shaft (34); tightening torque 5 da.Nm +
• the spacer (33)
• the gearbox shaft bracket (32)
• the bolts (31); tightening torque 1,9 da.Nm
• the gearbox flexible mounting (30)
• the gearbox shaft nut (28) and its washer
• the mounting bolts (29) (without tightening)

WARNING : centralise the power train before tightening the flexible mounting securing bolts .

Tighten :

• the bolts (29) to 3 da.Nm
• the nut (28) to 6,5 da.Nm

Fit :

• the battery tray support (27)
• the fasteners (26); tightening torque 1.9 da.Nm

Refit the alternator (19) .

Firstly tighten the bolts on the crankshaft pulley side to 4,1 da.Nm then the bolts on the oil filter side to 3,9 da.Nm .

Refit the torque reaction link (3) .

Tighten :

• the bolt (39) to 5 da.Nm
• the bolt (40) to 3,5 da.Nm

AIR CONDITIONING

Check the presence of the two spacers (41) .

WARNING : the anti-rotation nut (42) secures the compressor at its upper rear end .

Refit the compressor in the order of assembly shown above .

Firstly tighten the bolts on the crankshaft pulley side to 4.2 da.Nm then the bolts on the oil filter side to 4.1 da.Nm .

Re-connect the connector .

ALL MODELS

Refit the drive shafts .

Tighten the drive shaft nuts to 32.5 m.daN .

Fit : The ancillary drive pulley .

Clean the threads of the bolt of the pulley in the crankshaft by using a M16 X 150 tap .

Cleanthe thread of the bolt .

Tighten the bolt to 4 da.Nm + .

Finally tighten by turning through 51 ° (Using a FACOM D360 type tool) .

Check the tightening : 19.5 da.Nm .

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

Tighten (In order) :

• the bolt (43) to 2.5 da.Nm
• the bolt (44) to 2.5 da.Nm +
• the bolt (45) to 2.2 da.Nm

Continue the fitting operations in the reverse order to removal .

Refill :

• the gearbox
• the engine (if necessary)

Tighten the wheel bolts to 8.5 da.Nm .

Fill and bleed the cooling system .

Initialise the various ECUs .