B1BG12K1 - 607 DW12TED4 ENGINE

REMOVAL - REFITTING POWER UNIT

1 - SPECIAL TOOLS

[1] cross beam (-).0102-D .

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

[3] lifting hooks (-).0102-J/(-).0102-G .

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

[5] Tool for unclipping the ball joints d.10 mm (-).0216-G1 .

[6] Tool for unclipping the ball joints d.13 mm (-).0216-G2 .

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

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

2 - REMOVAL

The power unit is removed from above .

Remove the style covers .

Disconnect the battery .

Remove the excess pressure ducts (1) - (2) .

Remove the air cleaner (3) and its outlet connection .

Raise the vehicle .

Remove :

• the wheels
• the mud shields
• THE DRIVE SHAFTS
• THE ANCILLARY DRIVE BELT
• the tensioner roller (4) of the ancillaries drive belt

REMOVE THE VALVE SUPPORT .

Drain :

• THE COOLING SYSTEM
• the engine (if necessary)

ML GEARBOX

Drain the gearbox .

ALL MODELS

Remove the air conduit (5) .

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 .

Remove the torque reaction link (6) .

Remove the bolt (7) and the clip (8) from the air duct .

Block the hole of the turbo .

Disconnect the compressor electrical supply (9) .

Without disconnecting the hoses, move aside and clamp the air conditioning compressor (10) .

Unclamp the power steering circuit (11) (without opening the circuit) .

Remove the air cleaner bracket (12) and its sleeve .

Move aside the harness (13) .

Remove the protective shield (14) from the battery .

Uncouple the accelerator cable (15) .

Disconnect the accelerator potentiometer (16) connector .

Remove the screen (17) .

Remove the battery .

Remove the battery tray (18) .

Unclamp and move aside the connectors (19) and the relays (20) .

Remove the separation panel (21) .

Disconnect the connectors (22) .

Disconnect the cables (23) .

Remove the support (24) .

Move aside the harnesses (25) .

Disconnect the earth cables (26) .

Disconnect and remove the control unit(s) with their brackets .

Disconnect and move aside the harnesses attached to the engine .

Move aside the hoses (27) .

Remove the radiator .

Protect the condenser with strong cardboard .

Without disconnecting the hoses, move aside and clamp the power steering pump (28) .

Unclamp and move aside the fuel supply ducts (29) .

Plug the holes using tool [4] .

Disconnect and move aside the power steering pipes (30) .

Move aside the heat exchanger ducts (31) .

HP AUTOMATIC GEARBOX

Uncouple and move aside the gearbox control .

ML GEARBOX

Uncouple and move aside the gearbox controls using tools [5] - [6] .

Disconnect the clutch control pipe (32) .

IMPERATIVE : protect the ends of the pipe and the clutch slave cylinder using the tools [4] .

ALL MODELS

Position the cross beam [1] fitted with its chains [2] and take the weight .

Remove :

• the bolts (33) -(34)
• the torque reaction link (35)
• the nut (36)

Remove :

• the gearbox shaft nut (37) and its washer
• the mounting bolts (38)
• the gearbox flexible mounting (39)
• the spacer

Remove :

• the bolts (40) - (42)
• the bracket (41)

Remove the power unit from above .

3 - REFITTING

Proceed in the reverse order to removal .

Always renew :

• the Nyloc nuts
• the exhaust clip

Use the drifts [7] - [8] to fit the final drive oil seals, having greased the space between the seal lips .

Fit :

• the nut (36)
• the torque reaction link (35)
• the bolts (33) - (34)
• the bracket (41)
• the bolts (40)

Tighten :

• the bolts (40) to 2,7 da.Nm
• the bolts (33) - (34) to 5 da.Nm

Position the spacer on the gearbox shaft then coat it with PCAS SPAGRAM grease .

Position :

• the flexible mounting (39)
• the nut (37)
• the bolts (38)

Lower the power train on to its mountings .

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

IMPERATIVE : apply a counter-torque to the flexible mount shaft when tightening the nut (36) .

Tighten :

• the nut (36) to 4,5 da.Nm
• the nut (37) to 6,5 da.Nm
• the bolts (38) to 3 da.Nm

Refit the torque reaction link (6) .

Tighten :

• the bolt (42) to 5 da.Nm
• the bolt (43) to 5 da.Nm
• the nuts (44) to 1 da.Nm

Check the presence of the two spacers (45) .

WARNING : the anti-rotation nut (46) secures the compressor at its upper rear end .

REFIT THE COMPRESSOR IN THE ORDER OF ASSEMBLY SHOWN ABOVE .

Firstly tighten the bolts on the crankshaft pulley side to 4,2 da.Nm then the bolts on the oil filter side to 4,1 da.Nm .

Re-connect the connector (9) .

REFIT THE DRIVE SHAFTS .

Tighten the drive shaft nuts to 34,5 m.daN .

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

Tighten (In order ) :

• the bolts (47) - (49) to 2,16 da.Nm
• the bolt (48) to 2.16 da.Nm + LOCTITE FRENETANCH

Continue the fitting operations in the reverse order to removal .

Reconnect the the clutch control pipe (32) .

BLEED THE CLUTCH HYDRAULIC CIRCUIT .

FIT THE ANCILLARY DRIVE BELT .

Continue the fitting operations in the reverse order to removal .

REFIT THE SOLENOID VALVES BRACKET .

Refill :

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

Tighten the wheel bolts to 9 da.Nm .

FILL AND BLEED THE COOLING SYSTEM .

Initialise the various ECUs .