B1BG0ZK1 - 607 EW12J4 ENGINE

REMOVAL - REFITTING POWER UNIT

1 - SPECIAL TOOLS

EW12J4 ENGINE

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

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 .

2 - REMOVAL

EW12J4 ENGINE

The power unit is removed from above .

Place the bonnet in the parking position .

Remove :

• the style covers
• the exhaust expansion chamber
• the air cleaner and its outlet pipe

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
• the drive shafts
• the front right mud shield
• THE ANCILLARY DRIVE BELT

Disconnect the compressor electrical supply (8) .

Move aside the air conditioning compressor (8) without opening the system .

Disconnect the connector from the power steering circuit pressure sensor .

Move aside the power steering pipe (9) .

Disconnect :

• the pipe (10)
• the pipe (11)
• the pipe (12)

Unclamp and move aside :

• the pipe (13)
• the harness (14)

Remove : The 3 nuts (15) .

Move aside : The gearbox control plate (16) .

Move aside the power steering pump (17) without opening the circuit .

Disconnect and move aside : The pipe (18) .

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 (19)
• the pipe (20)

Remove :

• the 4 grille clips (21)
• the two top parts of the grille (22)

Remove : The 2 bolts (23) .

Retrieve the radiator securing clips .

Remove : The radiator .

Remove :

• the battery
• the battery side cover (24)

Uncouple the accelerator cable (25) .

Disconnect the accelerator potentiometer (26) .

Remove the accelerator potentiometer bracket (27) .

Disconnect :

• the reverse gear connector (28)
• the earth cable on the gearbox (29)

Disconnect :

• the double relay connector (30)
• the connector (31)
• the ecu connectors (32)
• the two cables (33) in the fusebox.

Remove :

• the ECU and its support (34)
• the battery tray (35)

Remove : The earth bolt (36) .

Disconnect the connector (37) .

Unclamp the air intake sleeve (38) from the air cleaner bracket (39) .

Unclamp and move aside the harnesses .

Move aside : The air cleaner bracket (39) .

Disconnect the clutch control pipe (40) .

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

Uncouple :

• the selector rod (41) (using the tool [1])
• the engagement link (42) (using the tool [1])

Remove the metal heat shield (43) .

Move aside : The heater matrix hoses (44) .

Remove :

• the 2 bolts (45), (46)
• the torque reaction link (47)
• the nut (48)

Fit the tool [4] .

Remove :

• the gearbox shaft nut (49) and its washer
• the bolts (50) for mounting (51)
• the gearbox flexible mounting (51)

NOTE : slightly lower the power train in order to access the bolts (52) for securing the gearbox pin plate (53) .

Remove :

• the 3 bolts (52)
• the gearbox pin plate (53)

Remove the power unit from above .

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 (53)
• the 3 bolts (52) (tightening torque : 4.5 da.Nm)

Fit :

• the gearbox flexible mounting (51)
• the 2 bolts (50) for the flexible mount (without tighterning)

WARNING : lower the tool [4] so that the power train is centred on the flexible mount .

Tighten :

• the bolts (50) : 3 da.Nm
• the nut (49) : 6.5 da.Nm

Fit :

• the nut (48) : 4.5 da.Nm

IMPERATIVE : apply a counter-torque at (A) .

Fit :

• the torque reaction link (47)
• the bolts (46), (45)

Tighten :

• the bolts (46) to 5 da.Nm
• the bolts (45) to 5 da.Nm

Position : The gearbox control plate (16) .

Tighten the nut (15) to 1.9 da.Nm .

Fit :

• the air conditioning compressor (8) (tightening torque : 2.5 da.Nm)

Fit :

• the drive shafts
• the torque reaction link (5)

Tighten :

• the nuts (6) to 1.35 da.Nm
• the bolt (4) 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 (54) to 2.5 da.Nm
• the bolt (55) to 2.5 da.Nm
• the bolt (56) to 2.2 da.Nm + LOCTITE FRENETANCH

Reconnect the the clutch control pipe (40) .

BLEED THE HYDRAULIC CLUTCH CONTROL .

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

FILL AND BLEED THE COOLING SYSTEM .

Initialise the various ECUs .