Note: Due to the complexity of the powertrain on these vehicles and the variety of situations you may encounter during operation depending on the model and optional equipment installed, the following description should be considered more of a guide rather than a step-by-step procedure. If during the work you encounter a discrepancy with the description or it is necessary to remove or disconnect. additional elements, make the necessary notes that will facilitate subsequent installation.
Caution: When working with fuel system components on a 2.0L engine, strict safety precautions must be observed. Before performing any of the following actions, refer to the specific information provided in paragraph 1 of chapter 4B.
Removal
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 backing plate as described in chapter 5A.
2. Apply the parking brake. Raise the front of the vehicle and support it securely (see "Lifting and installing the car on supports"). Remove both front wheels.
3. On 1.9L engines (DW series), release the fasteners on the right side and on the top plane of the engine cover, then remove the cover, being careful not to dislodge the associated rubber mounts. Rotate the four plastic clips 90° and remove the engine cover.
4. For better access, remove the hood as described in chapter 11.
Text taken from the website [www.PeugeotBook.ru]
5. Remove the air filter housing and air intake duct as described in Chapter 4B or 4B.
6. Drain the coolant from the cooling system (see Chapter 1B).
7. Drain the gearbox oil as described in chapter 7. Screw the drain and filler plugs back into place and tighten them to the specified torque.
8. If the engine must be disassembled, drain the engine oil and remove the oil filter as described in chapter 1B. Clean and screw in the drain plug. Tighten it securely.
9. Remove the wheel arch liners from the front wheels. The lockers are secured with various screws and fasteners. Remove all fasteners and remove the mudguards from under the front fenders.
10. Remove the accessory drive belt (see Chapter 1B).
11. Remove both front axle shafts (see chapter 8).
12. Disconnect the upper and lower radiator hoses, the heater hoses on the engine compartment bulkhead and the expansion tank hose. Remove the radiator as described in chapter 3.
13. On models with air conditioning, remove the compressor from the engine (refer to chapter 3). Do not disconnect the refrigerant lines. Support or tie the compressor off to the side.
14. On models with power steering, remove the power steering pump as described in chapter 10. Release the power steering line from the clamps on the underside of the transmission.
15. On 1.8L and 1.9L engines (XUD series), perform the following steps (see chapter 4B):
- a) Disconnect the fuel supply hose from the fuel filter/thermostat housing and the return hose from the high pressure fuel pump.
- b) Release the fuel hoses and the lift pump from their respective clamps and move them away from the engine.
- c) Disconnect the accelerator cable from the high pressure fuel pump.
- d) Disconnect the exhaust pipe/catalytic converter from the exhaust manifold.
16. On 1.9L and 2.0L engines (DW series), perform the following steps (see chapter 4B):
- a) Disconnect the quick release couplings of the fuel supply and return hoses at the connections near the fuel pump using a small screwdriver to release the retaining clip. Seal open ports to prevent dirt from entering using small plastic bags or "fingers" cut from clean rubber gloves.
- b) Release the fuel hoses from the corresponding clamps and move them away from the engine.
- c) Disconnect the accelerator cable from the high-pressure fuel pump or accelerator pedal position sensor (whichever is applicable).
- d) Disconnect the electrical connectors of the engine control unit.
- d) Disconnect the catalytic converter from the exhaust manifold/turbocharger.
17. Disconnect the vacuum hoses and disconnect the electrical connector at the EGR solenoid valve.
18. Unscrew the corresponding bolts and remove the pre-heating system control unit located on the front side of the engine compartment.
19. Open the fuse/relay box in the engine compartment and disconnect the corresponding engine electrical connectors.
20. Trace the wiring harness from the engine to the main wiring harness connectors at the fuse/relay box and/or to the bulkhead or dash panel connections. Release the locking rings by turning them counterclockwise and disconnect the electrical connectors. Also, trace the wiring back to the transmission and disconnect all engine related electrical connectors and all ground wires in this area. Ensure that all relevant electrical connectors are disconnected and the wiring harness is released from all clamps or ties so that the wiring harness can be removed freely along with the engine/transmission.
21. Disconnect the engine ground wires at the fuse box, under the left wheel arch and on the left chassis side member.
22. Disconnect the brake booster vacuum line from the vacuum pump or disconnect the quick release coupling on the line.
23. Disconnect the clutch cable from the release lever and the gearbox bracket as described in chapter 6.
24. Disconnect the gear shift drive from the gearbox as described in chapter 7.
25. Remove the front subframe as described in chapter 10.
26. Using a lifting device with slings/hooks connected to the lifting eyes on the cylinder head, remove the load from the engine and gearbox mounts.
27. Remove the right, left and rear engine mounts and support brackets as described in Chapter 2B or 2B (whichever is applicable).
28. Make one last check that all wires, hoses and brackets that could prevent the unit from being removed are disconnected.
29. Carefully lower the engine/gearbox out of the engine compartment, being careful not to damage adjacent components. Ideally, lower the unit onto a low dolly so that the unit can be removed from under the vehicle. Disconnect the lifting device slings/hooks from the engine and transmission assembly.
Separation
30. After removing the engine assembly with the gearbox, install the unit on a workbench on suitable wooden blocks (or on a clean section of the floor of the repair area of the service station).
31. Remove the bolts and remove the lower flywheel cover from the gearbox.
32. Unscrew the bolts and remove the starter from the gearbox.
33. Disconnect all remaining electrical connectors on the transmission, then move 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 removing them; this information will be needed 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 driven 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 gearbox have not been separated, 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 primary shaft of the gearbox. Do not apply too much grease as this may result in grease getting onto the clutch disc.
39. Make sure the dowel pins are present and installed correctly on the engine or gearbox.
40. Carefully position the gearbox towards the engine, ensuring that the pins are aligned with the mating holes. Make sure that the gearbox does not press with its weight on the input shaft when it engages the driven disc of the clutch.
41. Screw in the transmission housing mounting bolts to the engine, remembering to correctly position all the necessary brackets, and tighten the bolts to the specified torque.
42. Install the starter and tighten the corresponding bolts securely.
43. Install the lower flywheel cover onto the gearbox and tighten the bolts securely.
44. Position the engine and gearbox assembly ready for installation, then attach the lifting device slings/hooks to it. With the help of an assistant, insert 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 2B or 2B (whichever is applicable).
46. Disconnect the lifting device from the engine.
47. Install the front subframe as described in chapter 10.
48. 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) Properly route and secure all electrical wiring with clamps, and connect electrical connectors correctly and securely.
- b) Properly connect and securely clamp all disconnected coolant hoses.
- c) Fill the engine and gearbox with the prescribed oil in the correct quantity as described in the chapters 1B and 7.
- d) Fill the cooling system as described in chapter 1B.
- d) Fill and pressurize the fuel system as described in chapter 4B.
- e) Bleed the power steering system as described in chapter 10.