Note. Due to the complexity of the powertrain on these vehicles and the different situations you may encounter during operation depending on the model and optional equipment installed, the following description should be regarded as a guide rather than a step-by-step procedure. If during operation you encounter a discrepancy with the description or you need to remove or disconnect additional elements, make the necessary notes that will facilitate subsequent installation.
Removing
Note. The engine can only be removed from the vehicle together with the gearbox. The units can then be separated for repairs.
1. Remove the battery, battery tray, and base plate as described in chapter 5A.
2. Apply the parking brake. Raise the front of the vehicle and securely jack stands under it (see «Lifting and placing the car on supports»). Remove both front wheels.
3. Remove the plastic cover from the top of the motor (if applicable).
4. To improve access, remove the hood as described in chapter 11.
5. Remove the air cleaner housing and air intake duct as described in chapter 4A.
6. Drain the coolant from the cooling system (see chapter 1A).
7. Drain the gearbox oil as described in chapter 7. Replace the drain and filler plugs and tighten to the specified torque.
8. If the engine must be disassembled, drain the engine oil and remove the oil filter as described in chapter 1A. Clean and screw in the drain plug. Tighten it securely.
9. Remove the lockers from the wheel arches of the front wheels. Lockers are fastened with various screws and clamps. Remove all fasteners and remove the lockers from under the front fenders.
10. Remove the accessory drive belt (see chapter 1A).
11. Remove both front axle shafts (see chapter 8).
12. Disconnect the upper and lower radiator hoses, the heater hoses on the bulkhead of the engine compartment and the expansion tank hose. On models beginning September 2002, remove the heatsink as described in chapter 3.
13. On models with air conditioning, remove the compressor from the engine (refer to chapter 3). Do not disconnect refrigerant lines. Support or tie the compressor aside.
14. On models with power steering, remove the power steering pump as described in chapter 10.
15. Remove the exhaust system (see chapter 4A).
16. Mark the installation position and wiring harness, and then disconnect all relevant electrical connectors on the gearbox. If necessary, attach tags to electrical connectors before disconnecting them.
17. Disconnect the electrical connectors of the engine wiring harness at the fuse box, fuel injection relay and front panel of the body (whichever is applicable). Release the wiring harness from the clips and ties so that the wiring harness can be freely removed with the engine.
18. Disconnect the wires «masses» engine on the fuse box, under the left wheel arch and on the left side member of the chassis.
19. Disconnect the brake booster vacuum line from the intake manifold.
20. Disconnect the accelerator cable (see chapter 4A).
21. If applicable, on later engines, remove the two bolts securing the right engine mount reinforcement bracket to the body and remove the bracket together with the accelerator pedal position sensor.
22. Disconnect the fuel supply and return hoses and plug the hoses and ports to prevent dirt from entering. Release the fuel hoses from the clamps on the engine and move them to the side.
23. Disconnect the clutch cable from the release lever and transmission bracket as described in Chapter 6.
24. Disconnect the shift actuator from the gearbox as described in chapter 7.
25. Using a lifting device with slings/hooks connected to the lifting eyes on the cylinder head, relieve the engine and transmission mounts.
26. Remove the right, left, and rear engine mounts and support brackets as described in chapter 2A.
27. Make sure one last time that all wires, hoses and brackets that may prevent removal of the unit are disconnected.
28. On models manufactured before September 2002, remove the engine assembly with gearbox from the engine compartment, being careful not to pinch or damage any elements. Have a second person perform this procedure as the machine will need to be tilted slightly to avoid hitting the body panels. Once the implement has been raised to a sufficient height, lift it off the front of the body and lower it onto the prepared surface.
29. On models from September 2002, carefully lower the engine/transmission from the engine compartment, being careful not to damage adjacent components. Ideally, lower the unit onto a low cart so that the unit can be removed from under the vehicle. Disconnect the hoist straps/hooks from the engine/transmission assembly.
Separation
30. After removing the engine assembly with the gearbox, place the unit on a workbench on suitable wooden blocks (or to a clean area of the floor of the workshop of a service station).
31. Turn out bolts and remove the bottom cover of a flywheel (in the presence of) from the gearbox.
32. Turn out bolts and remove a starter from a transmission.
33. Disconnect all remaining electrical connectors on the transmission, and then take the main engine wiring harness to the side.
34. Make sure the engine and gearbox are stable, and then loosen and unscrew the remaining bolts securing the gearbox housing to the engine. Mark the position of each bolt (and corresponding brackets) when they are removed; this information will be required when installing them in place.
35. Carefully separate the gearbox from the engine, making sure that the gearbox does not press its weight on the input shaft, as it is engaged with the clutch disc.
36. If the dowel pins are easily removed from the engine or gearbox flange, remove them and store them in a safe place.
Installation
37. If the engine and transmission have not been separated from each other, follow the steps below, starting with step 44.
38. Apply some high temperature grease (Peugeot/Citroen recommends using Molykote BR2 plus) on the splines of the input shaft of the gearbox. Do not apply too much grease, as this may cause grease to get on the clutch disc.
39. Check that the dowel pins on the engine or gearbox are present and properly installed.
40. Carefully drive the gearbox towards the engine, making sure the pins are aligned with the mating holes. Make sure that the gearbox does not press its weight on the input shaft when it engages with the clutch disc.
41. Screw the bolts securing the gearbox housing to the engine, remembering to correctly position all the necessary brackets, and tighten the bolts to the prescribed torque.
42. Install the starter and securely tighten the appropriate bolts.
43. Install the lower flywheel cover (in the presence of) on the gearbox and tighten the bolts securely.
44. Position the engine/gearbox assembly ready for installation, and then attach the hoist straps/hooks to it. With the help of a second person, drive the unit into the engine compartment using the same procedure as for removal.
45. Install the right, left, and rear engine mounts and support brackets as described in chapter 2A.
46. Disconnect the lifting device from the engine.
47. The rest of the installation is carried out in the reverse order of removal, if necessary, referring to the relevant chapters and taking into account the following points:
- A) Correctly route and properly clamp all electrical wiring, connect electrical connectors correctly and securely.
- b) Connect and securely clamp all disconnected coolant hoses correctly.
- V) Fill the engine and gearbox with the prescribed oil in the correct quantity as described in chapters 1A and 7.
- G) Charge the cooling system as described in chapter 1A.
- d) Fill and pressurize the fuel system as described in chapter 4A.
- e) Bleed air from the power steering system as described in chapter 10.
- and) Perform the engine control ECU initialization procedure as described below. Start the engine and bring it up to normal operating temperature. Carry out a road test during which the following procedure must be carried out. Engage third gear and stabilize the engine speed at 1000 rpm. Then bring the speed up to 3500 rpm.