DW8 Engine — Removal and Installation (Peugeot 206)

When removing and installing the engine at Peugeot service centers, the following special tool is used:

• traverse - 0102-D
• flywheel stopper - 0188-F;
• hooks for hanging;
• gearbox rod release fork — 0102-G1/-G2;
• mandrel for installing oil seals - 0317-T/-U.

Removal

Remove the power unit with the DW8 engine in the following order:

Note: The power unit is removed upwards.

- set the hood cover to a vertical position using the device;

• remove decorative cover 5 (figure 4.16);
• remove block 4 of the air cleaner with air ducts;
• remove battery 3 with tray;
• remove preheating unit 2;
• unscrew two bolts 7;
• remove block 1 relay;
• remove the air filter housing;
• remove the battery tray support;
• disconnect and move aside the 6 fuel supply pipe fittings;
• remove the electronic control unit;

• disconnect wires 1 and 2 (figure 4.17);

• disconnect tubes 1, 2, 3 (figure 4.18);
• remove the front wheels;
• drain the oil from the gearbox;
• drain the coolant from the cooling system;
• remove mudguards;
• remove the protective screen under the engine;
• remove the front wheel drives from both sides of the vehicle;

• disconnect pin connector 1 (figure 4.19) on the inner panel of the left front fender;

• release and move aside tubes 1 (figure 4.20) power steering, passing in the engine area;
• remove the protective board 2;
• disconnect the exhaust pipe from the exhaust manifold side;

• install clamp 1 (figure 4.21);

• remove the jet bracket 1 (figure 4.22) engine mounts;

• without opening the refrigeration circuit of the air conditioning system, move compressor 1 to the side (figure 4.23);

Caution: Never bend the air conditioning system refrigeration circuit pipes.

• remove the front panel;
• move the power steering pump away without opening the system circuit;
• disconnect and move aside the heat exchanger pipes at the level of the shield;
• disconnect and move aside the brake booster hose;

• move the tank 1 (figure 4.24) along with his pipes;
• move the flexible clutch cable or the clutch slave cylinder to the side;
• disconnect the transmission control rods using the tool;
• cover the air conditioning condenser core tubes with a sheet of heavy-duty cardboard;
• remove the accessory drive belt;
• remove the generator;
• remove the crankshaft pulley;

• bring the lifting beam with hooks, hook the hooks onto lifting brackets 1 and 3 (figure 4.25), and then tighten the cables;
• unscrew three bolts 2;
• unscrew nut 9;
• remove the right engine mount bracket 8;
• unscrew nut 6;
• unscrew two bolts 7;
• remove elastic pad 4;
• unscrew the two bolts 5 securing the support;
• remove the caliper;
• disconnect and move aside the wiring harnesses, pipes related to the gearbox or engine;

• remove the power unit upwards, preserving the bushing 1 (figure 4.26).

Installation

Install the power unit with the DW8 engine in the reverse order of removal, while observing the following:

• systematically replace the self-locking nuts and seals at the gearbox outlet using mandrels;

Caution! Before installing the seals, pack the space between the edges with grease.

• install the compressor following the installation sequence of the above parts;

Attention! Lock nut 1 (see figure 4.14) secures the rear upper part of the compressor.

• first tighten the crankshaft pulley bolts to 42 N·m, then tighten the oil filter bolts to 39 N·m;
• carefully observe the routing and attachment points of wire bundles and wiring harnesses;
• bring the gearbox oil level up to normal;
• fill the engine cooling system and bleed air from it;
• perform programming of all electronic devices.