B1BG28K1 - 307 DW10TD ENGINE

REMOVAL - REFITTING POWER UNIT

1 - SPECIAL TOOLS

[1] Lifting table (-).0004 .

[2] Set of brackets for retaining power train (-).0005 .

[3] Tool for unclipping ø 10 mm ball joints (-).0216-G1 .

[4] Tool for unclipping ø 13 mm ball joints (-).0216-G2 .

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

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

[7] Final drive output oil seal fitting drifts (-).0317-T / (-).0317-U .

2 - REMOVAL

Place the vehicle on a two-post ramp .

WARNING : the power unit is removed via the front of the vehicle .

Disconnect the battery .

Remove the shield under the power train .

Drain :

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

Remove :

• the front wheels
• the front mud guards
• the drive shafts
• THE ANCILLARY DRIVE BELT

Disconnect the exhaust pipe from the turbocharger .

Remove :

• the torque reaction link (1)
• the subframe impactor reinforcer (4)
• the impactor (3)

Remove :

• the style covers (5) - (6)
• the battery (7) and its bracket ; access to a bolt via the left side wheel arch
• the air cleaner (8)

Disconnect the 32 way grey connectors and the 48 way brown connectors from the ecu .

Disconnect the cables (9) - (10) and the black 2 way connector (11) .

Remove :

• the headlamp washes ; (ACCORDING TO SPECIFICATION)
• THE FRONT BUMPER
• THE HEADLAMPS
• the front panel upper crossmember
• the accelerator cable and the pedal sensor
• the pre-heater unit

Remove and move aside the bonnet lock .

Using the tool [3] -[4], unclip the gear shift control ball joints .

Move aside :

• the brake servo vacuum pipe
• the heater matrix hoses
• the priming pump

WARNING : cover the fuel connectors so that they are adequately sealed .

Disconnect the electric supply from the fan unit .

Remove :

• the cooling radiator
• the front panel
• the lower crossmember of the front panel

Without disconnecting the pipes, move aside and clamp :

• the air conditioning capacitor
• THE AIR CONDITIONING COMPRESSOR (2)
• the clutch slave cylinder

Install the lifting table [1] with the brackets [2] under the power train .

Slacken the bolts (12) - (13) .

Remove the right-hand engine mounting .

Slacken the nuts (14) - (15) .

Remove the flexible shim from the left bracket (16) .

Using the tool [6], remove the pin from the left bracket .

Remove the power train .

3 - REFITTING

Always renew :

• the Nyloc nuts
• the exhaust clip

Use the drifts [7] to fit the final drive oil seals, having greased the space between the seal lips .

Introduce the power train with the lifting plate into the vehicle .

Refit the right-hand engine mounting .

Tighten :

• the bolts (12) by hand
• the bolts (13) to 6 da.Nm

Replace the left bracket and its washer using the tool [6] .

Tighten the shaft to 5 da.Nm .

Replace the flexible shim from the left bracket (16) .

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

Tighten :

• the nuts (14) to 3 da.Nm
• the nut (15) to 6.5 da.Nm
• the bolts (12) to 6 da.Nm

Remove the lifting table and the brackets from the power train .

Fit :

• the subframe impactor reinforcer
• the impact device tilting the bottom of the power train towards the front

Tighten :

• the bolts (19) to 4 da.Nm
• the bolt (20) to 6 da.Nm
• the nuts (21) to 4 da.Nm

Refit the torque reaction link (1) .

Tighten :

• the bolt (17) to 5.5 da.Nm
• the bolt (18) to 4 da.Nm

AIR CONDITIONING

REFIT THE COMPRESSOR .

ALL MODELS

Refit the drive shafts .

Continue the fitting operations in the reverse order to removal .

Fill or top up :

• the gearbox
• the engine (if necessary)

Tighten the wheel bolts to 9 da.Nm .

DRAIN AND RE-PRIME THE DIESEL CIRCUIT .

Initialise the various ECUs .

FILL AND BLEED THE COOLING SYSTEM .