B1BG0ZK1 - 406D9 EW10J4 ENGINE EW12J4 ENGINE

REMOVAL - REFITTING POWER UNIT

1 - SPECIAL TOOLS

EW12J4 ENGINE EW10J4 ENGINE

[1] Forks for removing gearbox control rods (-).0216-G1/(-).0216-G2 .

EW12J4 ENGINE

[2] fitting drift for final drive right-hand output oil seal (-).0332-A .

[3] fitting drift for final drive left-hand output oil seal (-).0332-B .

[4] Load balancer (Approved items of equipment of the NAUDER 1805 type) .

[5] Pipe with adapter for valve SHRADER (-).0141-T1 .

[6] Set of plugs (-).0188-T .

EW10J4 ENGINE

[2] fitting drift for final drive right-hand output oil seal (-).0317-U .

[3] fitting drift for final drive left-hand output oil seal (-).0317-T .

[4] Socket for the removal of the gearbox shaft (-).0317-AB .

[5] Load balancer (Approved items of equipment of the NAUDER 1805 type) .

[6] Pipe with adapter for valve SHRADER (-).0141-T1 .

ALL MODELS

2 - REMOVAL

EW12J4 ENGINE

The power unit is removed from above .

Place the bonnet in the parking position .

Disconnect :

• the battery
• the oxygen sensor connectors (1)
• the pipe (2)

Remove the shield under the power train .

Drain :

• the cooling system
• the gearbox
• the engine (if necessary)

IMPERATIVE : remove the exhaust pipe to avoid damaging the flexible hose; this cannot withstand the torsion, traction or bending tensions caused by the removal of one of the power train supports .

Slacken the bolts (3) and (4) .

Remove the torque reaction link (5) .

Slacken the nuts (6) .

Turn the bolts (7) half a turn to release their heads from the bearing housing .

Lift and support the front of the vehicle .

Remove the wheels .

Move aside the mud-shields .

Remove the drive shafts .

Remove :

• THE ANCILLARY DRIVE BELT
• the ancillary drive pulley

Disconnect the compressor electrical supply (8) .

Move aside the air conditioning compressor (9) without opening the system .

Disconnect the connector from the power steering circuit pressure sensor .

Move aside the power steering pipe (10) .

Disconnect the pipe (11) .

Disconnect the pipe (12) .

Remove the 3 nuts (13) .

Move aside : The gearbox control plate (14) .

Remove :

• the exhaust expansion chamber
• the air cleaner and its outlet pipe
• the style cover (15)

Move aside the power steering pump (16) without opening the circuit .

Move aside : The pipe (17) .

Disconnect the pipe from the canister (18) .

Lower the fuel pressure by connecting the end of the tool [5] to the valve SHRADER; catch the fuel in a receptacle .

Disconnect the pipe and the canister connector (19) .

Disconnect the connector from the double relay (20) .

Disconnect the connectors (21) from the ecu (22) .

Remove the control unit (22) .

Remove the tray (23) .

Move aside the brake assistance pipe (24) .

Move aside :

• the fuel connection (25)
• the earth cable (26)

Remove the torque reaction link (27) .

NOTE : retrieve the yoke (28) .

Remove the nut (29) .

Uncouple :

• the selector rod (30) (using the tool [1])
• the engagement link (31) (using the tool [1])

Remove :

• the air cleaner bracket (32)
• the air intake sleeve (33)

Disconnect the clutch control pipe (34) .

IMPERATIVE : protect the ends of the pipe and the clutch slave cylinder using the tools [6] .

Disconnect the connector (35) .

Disconnect the cable (36) .

Remove :

• the battery
• the battery container

Disconnect the earth cable (37) .

Disconnect the connector (38) .

Uncouple the connector (38) from the connector bracket (39) .

Unscrew the connector bracket (39) .

Move aside : The heater matrix hoses (40) .

Fit the tool [4] .

Remove : The gearbox shaft nut (41) and its washer .

NOTE : slightly lower the power train in order to access the bolts for securing the gearbox pin plate .

Remove :

• the 3 bolts (42)
• the gearbox pin plate (43)

Protect the radiator honeycomb with strong cardboard cut to the dimensions of the radiator .

Remove the power unit from above .

EW10J4 ENGINE

Disconnect :

• the battery
• the oxygen sensor connector

NOTE : the power unit is removed from above .

Remove the shield under the power train .

Drain :

• the cooling system
• the gearbox
• the engine (if necessary)

IMPERATIVE : remove the exhaust pipe to avoid damaging the flexible hose; this cannot withstand the torsion, traction or bending tensions caused by the removal of one of the power train supports .

Slacken the bolts (1) and (2) .

Remove the torque reaction link (3) .

Slacken the nuts (4) .

Turn the bolts (5) half a turn to release their heads from the bearing housing .

Lift and support the front of the vehicle .

Remove the wheels .

Move aside the mud-shields .

Remove the drive shafts .

Remove :

• THE ANCILLARY DRIVE BELT
• the ancillary drive pulley

Disconnect the compressor electrical supply .

Move aside the air conditioning compressor (6) without opening the system .

Move aside the power steering pipe (7) .

Disconnect the pipe (8) .

Move aside the harnesses (9) .

Remove :

• the air cleaner and its outlet pipe (10)
• the style cover (11)

Disconnect the pipe and the canister connector (12) .

Disconnect the connector (13) .

Remove the control unit (14) .

Remove the tray (15) .

Move aside the power steering pump (16) without opening the circuit .

Move aside :

• the pipe (17)
• the accelerator cable (18)

Lower the fuel pressure by connecting the end of the tool [6] to the valve SHRADER; catch the fuel in a receptacle .

Move aside :

• the fuel connection (19)
• the earth cable (20)

Remove the torque reaction link (21) .

NOTE : retrieve the yoke (22) .

Remove the nut (23) .

Remove :

• the clutch slave cylinder
• the air cleaner bracket

Disconnect the connector (24) .

Disconnect the cable (25) .

Uncouple :

• the selector rod (26) (using the tool [1])
• the engagement link (27) (using the tool [1])

Remove the 2 bolts (28) .

Remove the nut (29) .

Move aside : The gearbox control plate (30) .

Move aside : The heater matrix hoses (31) .

Fit the tool [5] .

Remove :

• the gearbox shaft nut (32) and its washer
• the mounting bolts (33)
• the gearbox flexible mounting (34)
• the spacer
• the gearbox shaft (35) and its washer using tool [4]

Protect the radiator honeycomb with strong cardboard cut to the dimensions of the radiator .

Remove the power unit from above .

ALL MODELS

3 - REFITTING

Always renew :

• the Nyloc nuts
• the exhaust clip

Use the drifts [2], [3] to fit the final drive oil seals, having greased the space between the seal lips .

Position the power train .

EW12J4 ENGINE

Fit :

• the gearbox pin plate (43)
• the 3 bolts (42) (tightening torque : 4.5 da.Nm)

Fit : The gearbox shaft nut (41) and its washer (Tightening torque : 6.5 da.Nm) .

Refit the nut (29) : Tightening torque 4.5 da.Nm .

Fit :

• the torque reaction link (27)
• the yoke (28)

Tighten :

• the bolt (44) to 4.5 da.Nm
• the bolt (45) to 4.5 da.Nm

Position : The gearbox control plate (14) .

Tighten the 3 nuts (13) to 1.9 dan.m .

Reconnect the the clutch control pipe (34) .

bleed the hydraulic clutch control .

Fit :

• the air conditioning compressor (8) : tightening torque : 2.5 da.Nm
• the ancillary drive pulley : tightening torque : 2 da.Nm

Fit :

• the drive shafts
• the torque reaction link (4)

Tighten :

• the nuts (5) to 1.35 da.Nm
• the bolt (2) to 8.5 da.Nm
• the bolt (3) to 4.5 da.Nm
• the drive shaft nuts to 32.5 da.Nm.

Fit : The exhaust pipe .

Refit the pump respecting the order of assembly of the components .

Tighten in the order :

• the bolt (46) to 2.5 da.Nm
• the bolt (47) to 2.5 da.Nm + LOCTITE FRENETANCH
• the bolt (48) to 2.2 da.Nm

EW10J4 ENGINE

Refit the nut (23) (Tightening torque 4.5 da.Nm) .

Fit :

• the spacer
• the gearbox shaft (35) and its washer using tool [4] (tightening torque 5 da.Nm)
• the gearbox flexible mounting (34)
• the gearbox shaft nut (32) and its washer
• the mounting bolts (33) (without tighterning)

WARNING : centralise the power train before tightening the flexible mounting securing bolts .

Tighten :

• the nut (32) : 6.5 da.Nm
• the bolts (33) : 3 da.Nm

Fit :

• the torque reaction link (21)
• the yoke (22)

Tighten :

• the bolt (36) to 4.5 da.Nm
• the bolt (37) to 4.5 da.Nm

Position : The gearbox control plate (30) .

Tighten the nut (29) to 1.5 da.Nm .

Tighten the bolts (28) to 2 daN.m .

Fit : The clutch slave cylinder; Tightening torque : 2 da.Nm .

bleed the hydraulic clutch control .

Fit :

• the air conditioning compressor (6) (tightening torque : 2.5 da.Nm)
• the ancillary drive pulley (tightening torque : 2 da.Nm)

Fit :

• the drive shafts
• the torque reaction link (3)

Tighten :

• the nuts (4) to 1.35 da.Nm
• the bolt (2) to 8.5 da.Nm
• the bolt (1) to 4.5 da.Nm
• the drive shaft nuts to 32.5 da.Nm.

Fit : The exhaust pipe .

Fit : Refit the pump respecting the order of assembly of the components .

Tighten in the order :

• the bolt (38) to 2.5 da.Nm
• the bolt (39) to 2.2 da.Nm
• the bolt (40) to 2.2 da.Nm + LOCTITE FRENETANCH

ALL MODELS

Continue the fitting operations in the reverse order to removal .

Refill :

• the gearbox
• the engine ( if necessary)

Tighten the wheels to 9 daN.m .

EW12J4 ENGINE EW10J4 ENGINE

FILL AND BLEED THE COOLING SYSTEM .

ALL MODELS

Initialise the various ECUs .