B1BG1HK1 - 307 TU3JP ENGINE TU5JP4 ENGINE

REMOVAL - REFITTING POWER UNIT

1 - SPECIAL TOOLS

[1] Lifting table (-).0004 .

[2] Fitting drifts for final drive outlet lip seals (-).0317-T and (-).0317-U .

[3] Power train/elevating platform connecting rod (-).0005-B .

[4] Rod/power train connecting tool (-).0005-C .

[5] Rod/power train connecting tool (-).0005-E .

[6] Rod/power train connecting tool (-).0005-F .

2 - REMOVAL

Open the bonnet to the workshop position and support it using a bolt/nut assembly .

Drain :

• THE COOLING SYSTEM
• THE GEARBOX
• engine (if necessary)

TU3JP ENGINE

TU5JP4 ENGINE

ALL MODELS

Move aside the brake fluid reservoir (1) .

Remove :

• the windscreen wipers
• the plastic windscreen deflector (2)
• the style covers (3)
• the plastic reinforcing crossmember (4)
• the air filter assembly, air inlet neck and expansion chamber (5)
• the right wheel arch mud guard
• the battery (6) and its bracket

Remove :

• THE FRONT BUMPER
• THE HEADLAMPS
• the front panel crossmember (7)
• the complete cooling box (8) with the radiator

Move aside and clamp the air conditioning radiator .

Remove the panel lower crossmember (9) .

Do not allow the horn to hang at the end of its harness .

Lower the pressure in the injection rail using the valve SCHRADER .

Disconnect the harnesses and the fuel supply pipe adjoining the engine .

Remove :

• the catalytic converter
• THE ANCILLARY DRIVE BELT

Move aside and clamp the air conditioning compressor .

Remove the air conditioning compressor support .

Remove :

• the bolts (10)
• the steering ball joint

Unclamp the abs sensor .

Move aside the wheel hub assembly .

Remove the drive shafts .

Clamp the wheel hub assembly .

Remove :

• the clutch slave cylinder (11)
• the subframe impactor reinforcer (12)

Remove :

• the gearbox control ball joints (13)
• the wiring support (14)
• the heater matrix pipes
• the earthing connection (15)
• the engine electrical harnesses at the ecu and the gearbox

Fit the pins on the elevator platform ( As indicated) :

• the pin [4] is secured in place of the reaction link rod
• the pin [5] is secured in place of the bolt securing the catalytic converter on the engine block
• the pin [6] is positioned on the air conditioning compressor support fixings
• the pin [3] is positioned in place of the bolt securing the catalytic converter on the block
• lift the platform to place the pins under stress

Remove :

• the right-hand engine mounting
• the gearbox flexible mounting
• the power train from the front

3 - REFITTING

Proceed in the reverse order to removal .

Always fit new Nyloc nuts .

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

Coat the left engine mounting pin (16) with grease SPAGRAH .

Position the power train .

Tighten the left engine mounting nut to 6.5 dan.m .

TU3JP ENGINE

TU5JP4 ENGINE

ALL MODELS

Refit the right-hand engine mounting .

Proceed in the reverse order to removal .

Refit the torque reaction link .

FIT THE ANCILLARY DRIVE BELT .

Refit the drive shafts .

Fill or top up :

• THE GEARBOX
• the engine (if necessary)

Fit :

• THE FRONT BUMPER
• THE HEADLAMPS

FILL AND BLEED THE COOLING SYSTEM .