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 .