B1CG00K1 - 206 TU ENGINE

REMOVAL - REFITTING POWER UNIT

1 - SPECIAL TOOLS

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

[2] Lifting chain (-).0102-M - 2517-Tbis .

[3] Set of 2 hooks (-).0102-G .

[4] fitting drift for final drive right-hand output oil seal (-).0317-U .

[5] fitting drift for final drive left-hand output oil seal (-).0317-T .

[6] Vacuum pump FACOM DA.16 - 4530-TG .

2 - REMOVAL

Drain :

• THE COOLING SYSTEM
• the engine

5 GEARBOX

Drain : The gearbox .

ALL MODELS

Remove :

• the battery (1)
• air inlet/air filter neck unit (2)
• the injection-ignition control unit (3)
• the battery container (4)
• the battery tray
• the accelerator cable (5)
• the engine coolant outlet/radiator inlet pipes

Disconnect :

• the electrical connections (6)
• the inertia switch (7)
• the earth point (8) on the left chassis leg

Remove the clutch cable .

Disconnect the connector (9) .

Unclamp the pipes (10) on the bulkhead .

Disconnect the electrical connection (11) .

Remove the gearbox controls .

Uncouple the click-on clip (12) on the vacuum take-off for the braking assistance on the inlet manifold .

Lower the pressure in the injector supply pipe by means of the pump [6] .

Disconnect the click-on connectors for fuel supply and return on the injection rail .

Remove :

• the front right-hand wheel
• the mud shield (right side)

Disconnect and unclamp the connector on the lambda sensor (13) .

Remove :

• the catalytic converter (14)
• the heat shield (15)
• THE DRIVE SHAFTS

POWER STEERING

Remove :

• THE ANCILLARY DRIVE BELT
• the power steering pump fixing bolts
• the heat shield fixing bolts (16)

Move aside the power steering pump without opening the high pressure pipes .

AIR CONDITIONING

Remove the compressor securing bolts .

Move aside the air conditioning compressor without opening the pipes .

Disconnect the connector located under the coolant reservoir .

ALL MODELS

ALL MODELS

Remove the bolt securing the reaction link (17) to the body .

Position the lifting tools [1] - [2] - [3] and switch them on .

Remove :

• the flexible mounting (18)
• the bracket (19)

Move aside the gearbox mounting plate (20) .

Remove :

• the engine mounting (21)
• the cooling radiator

Protect the cooling radiator with stiff cardboard .

Remove the power train from below the vehicle .

3 - REFITTING

IMPERATIVE : always fit new Nyloc nuts .

Use the drifts [4] - [5] to fit the final drive oil seals, having greased the space between the seal lips .

Ensure that the spacer (22) is present .

Grease the inner part of the gearbox flexible mount with grease .

Fit :

• the flexible mounting
• the right-hand engine mounting (21)

AIR CONDITIONING

When refitting the compressor, tighten the securing bolts on the pulley side first .

5 GEARBOX

Fill the gearbox .

ALL MODELS

REFIT THE DRIVE SHAFTS .

Fill the engine oil and check the level .

Check the cooling system for leaks .

Connect the battery .

FILL AND BLEED THE COOLING SYSTEM .

FIT THE ANCILLARY DRIVE BELT .

Continue the fitting operations in the reverse order to removal .

Turn on the ignition for 10 seconds .

Carry out the initialisation procedure for the injection ignition control unit .