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 you need to remove or disconnect additional elements, make the necessary notes that will facilitate subsequent installation.
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. Remove the plastic cover from the top of the engine (if applicable).
4. For better 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. 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 1A. 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 1A).
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. On models from September 2002 onwards, 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.
15. Remove the exhaust system (see chapter 4A).
16. Mark the installation position and wiring harness routing, and then disconnect all related electrical connectors on the transmission. 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 body panel (whichever is applicable). Release the wiring harness from the clamps and ties so that the wiring harness can be removed freely along with the engine.
18. Disconnect the engine ground wires at the fuse box, under the left wheel arch and on the left chassis side member.
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 gearbox bracket as described in Chapter 6.
24. Disconnect the gear shift drive 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, remove the load from the engine and gearbox mounts.
26. Remove the right, left and rear engine mounts and support brackets as described in chapter 2A.
27. Make one last check that all wires, hoses and brackets that could prevent the unit from being removed are disconnected.
28. On models produced before September 2002, remove the engine and transmission assembly from the engine compartment, taking care not to pinch or damage any components. Have an assistant assist you with this procedure as you will need to tilt the unit slightly to avoid hitting the body panels. Once the unit is raised to a sufficient height, lift it off the front of the vehicle and lower it onto the prepared surface.
29. On models from September 2002 onwards, carefully lower the engine/transmission 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. Unscrew the bolts and remove the lower flywheel cover (if available) 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.
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 (if available) 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 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) 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 1A and 7.
- d) Fill the cooling system as described in chapter 1A.
- d) Fill and pressurize the fuel system as described in chapter 4A.
- e) Bleed the power steering system as described in chapter 10.
- g) Perform the engine control ECU initialization procedure as described below. Start the engine and bring it to normal operating temperature. Perform a road test during which the following procedure must be completed. Shift into third gear and stabilize the engine speed at 1000 rpm. Then increase the speed to 3500 rpm.