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 require removal or disconnection. additional items, make the necessary notes to facilitate subsequent installation.
Attention! Strict precautions must be observed when working on fuel system components on a 2.0L engine. Before performing any of the following operations, refer to the specific information given in paragraph 1 of chapter 4B.
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. On engines 1.9 l (DW-series) release the clips on the right side and on the top plane of the engine cover, and then remove the cover, being careful not to fall out of the corresponding rubber supports. Rotate the four plastic tabs 90°and remove the engine cover.
4. To improve access, remove the hood as described in chapter 11.
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. 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 1B. 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 1B).
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. 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. Release the power steering line from the clips on the underside of the transmission.
15. On engines 1.8 l and 1.9 l (XUD series) do the following (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 booster pump from their respective clips and move them away from the engine.
- V) Disconnect the accelerator cable from the high pressure fuel pump.
- G) Disconnect the front exhaust pipe/catalytic converter from the exhaust manifold.
16. On engines 1.9 l and 2.0 l (DW-series) do the following steps (see chapter 4B):
- A) Disconnect the fuel supply and return hose quick couplers at the connections near the fuel pump using a small screwdriver to release the locking 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 appropriate clamps and take them away from the engine.
- V) Disconnect the accelerator cable from the high pressure fuel pump or accelerator pedal position sensor (whichever is applicable).
- G) Disunite electric sockets of the block of electronic management of the engine.
- d) Disconnect the catalytic converter from the exhaust manifold/turbocharger.
17. Disconnect the vacuum hoses and disconnect the electrical connector on the EGR solenoid valve.
18. Turn out corresponding bolts and remove the block of management of system of preheating located on the front side of engine compartment.
19. Open the engine compartment fuse/relay box and disconnect the appropriate engine electrical connectors.
20. Trace the wiring harness from the engine to the main wiring harness connectors in the fuse/relay box and/or connections on the bulkhead or front body panel. Release the retaining rings by turning them counterclockwise and disconnect the electrical connectors. Also trace the electrical wiring to the gearbox and disconnect all electrical connectors related to the engine and disconnect all wires «masses» in this zone. Make sure that all relevant electrical connectors are disconnected and that the wiring harness is released from any clips or ties so that the wiring harness can be freely removed with the engine/transmission.
21. Disconnect the wires «masses» engine on the fuse box, under the left wheel arch and on the left side member of the chassis.
22. Disconnect the vacuum line of the vacuum brake booster from the vacuum pump or disconnect the quick coupling on the line.
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. 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, relieve the engine and transmission 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 sure one last time that all wires, hoses and brackets that may prevent removal of the unit are disconnected.
29. 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 from a transmission.
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 cord driven 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 to the transmission and securely tighten the bolts.
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 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) 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 1B and 7.
- G) Charge the cooling system as described in chapter 1B.
- d) Fill and pressurize the fuel system as described in chapter 4B.
- e) Bleed air from the power steering system as described in chapter 10.