B1BG1GK1 - 406D9 ES9J4S ENGINE

REMOVAL - REFITTING POWER UNIT

1 - SPECIAL TOOLS

[1] Cross beam (-).0135 A .

[2] Lifting chain (-).0102 M .

[3] final drive output oil seal fitting drifts (-).0332 A (-).0332 B .

[4] Tool for unclipping 10 dia. ball joints (-).0216 G1 .

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

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

2 - REMOVAL

The power unit is removed from above .

Place the bonnet in the parking position .

Remove :

• THE STYLE COVER
• the ecu holder cover
• the battery side cover

Disconnect the battery .

REMOVE THE INLET MANIFOLD (1) .

Remove :

• the bolt (2)
• the bolt (3)

Disconnect the pipe and the canister connector (4) .

Disconnect the double relay connector (5) .

Disconnect the connectors (6) from the ecu (7) .

Remove the control unit (7) .

Remove the tray (8) .

Move aside the harnesses .

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

Move aside the pipe (9) .

REMOVE THE ANCILLARY DRIVE BELT .

Remove :

• the (10) mounting bolts for the power steering high pressure pipe
• the bolt (11)
• the bolts (12)

Disconnect the connector (13) from the power steering circuit pressure sensor .

Move aside the power steering pump .

Remove :

• the lower torque reaction rod cooling scoop
• the shield under the power train

Drain :

• THE COOLING SYSTEM
• the engine (if necessary)

REMOVE THE DRIVE SHAFTS .

Unclip the power steering pipe (14) .

Disconnect the compressor electrical supply .

Unclamp the air conditioning pipe .

Move aside the air conditioning compressor (15) with its securing bracket without opening the fluid circuit .

Remove the crankshaft pulley (16) .

Move aside the coolant hose (17), engine side .

REMOVE FRONT AND REAR PRECATALYTIC CONVERTERS .

Remove the lower torque reaction rod .

Disconnect the pipe (18) and move it aside .

Disconnect the heat matrix connectors (19) .

Disconnect the clutch control pipe (28) .

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

Remove :

• the air inlet sleeve (29) with its bracket
• the battery
• the battery container (32)

Move aside :

• the de-hydrator reservoir (30) without opening the refrigerant circuit
• the throttle potentiometer (31) and its bracket

Remove the nut (33) .

Disconnect the connectors (34)-(35) .

Loosen the base of the connector (35) on its support (36) .

Move aside the bracket (36) .

Unclamp the pipes (37) At (A)-(B) .

Move aside the anti-lock unit (38), taking care not to damage the rigid pipes .

Remove the bolt (39) .

Unclamp and move aside the harnesses (40) .

Disconnect the pipes (41) .

Remove the radiator .

Remove the 2 mounting bolts (42) on the gearbox control cable adjustment bracket .

Unclip the link (43) .

Separate control cable take-up support by turning rings (44) and (45) in direction indicated, push ring (46) back into place .

Move aside The control cable .

Using the tool [4], unclip the swivel joints (47) - (48) .

Remove :

• the torque reaction link (49)
• the engine mounting (50)

Remove :

• the nut (51)
• the 2 bolts (52)
• the flexible mounting (53)
• the 4 bolts (54)
• the gearbox seating (55)
• remove the power unit from above

3 - REFITTING

Always renew :

• the exhaust clip
• metal seals of precatalytic converters
• the Nyloc nuts
• the fixing nuts for the pre-catalyser
• the final drive output lip seals using the tools [3]

Lower the power unit .

Fit :

• the gearbox seating (55)
• the 4 bolts (54) : tightening torque 2.5 da.Nm

Position the power train .

Fit :

• the flexible mounting (53)
• the 2 bolts (52) without tighterning
• the nut (51)

Fit :

• the engine mounting (50)
• the 3 bolts (56) : tightening torque 6 da.Nm
• the torque reaction link (49)
• the bolt (58) : tightening torque 4.5 da.Nm
• the bolt (59) : tightening torque 5 da.Nm

Lower the power train on to its mountings .

Tighten :

• the bolts (52) to 3 da.Nm
• the nut (51) to 6.5 da.Nm
• the nut (57) to 4.5 da.Nm

Remove the tools .

Fit the bottom engine mounting torque reaction rod .

Tighten :

• the bolt (60) to 5 da.Nm
• the bolt (61) to 5 da.Nm

REFIT THE DRIVE SHAFTS .

Tighten the drive shaft nuts to 24.5 m.daN .

FILL AND BLEED THE COOLING SYSTEM .