B1BG15K1 - 607 ES9J4S ENGINE EMISSION CONTROL CEE 2000

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 the ball joints (Diameter 10) (-).0216-G1 .

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

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

2 - REMOVAL

The power unit is removed from above .

Remove :

• the front wheels
• the front right mud shield
• the protective housing under the engine
• STYLE COVER (1)
• the style covers (2) - (3) - (4) - (5)

NOTE : slightly push in the central pin of the bracket so that this is still retained by the claws of the bracket .

Drain :

• THE COOLING SYSTEM
• the engine (if necessary)

ML5T GEARBOX

Drain the gearbox .

REMOVE THE DRIVE SHAFTS .

4HP20 AUTOMATIC GEARBOX

Do not drain the gearbox .

REMOVE THE DRIVE SHAFTS .

ALL MODELS

Unclamp :

• the power steering pipe (en A - B)

Disconnect the battery .

Remove :

• THE ANCILLARY DRIVE BELT
• the power steering pump pulley
• THE ALTERNATOR

Remove :

• the 5 nuts on the exhaust clamp (6)
• the complete exhaust pipes

Remove the ventilation cover (8) from the lower mounting after removing the plastic rivet (9) .

Remove the lower reaction link rod (7) .

REMOVE FRONT AND REAR PRECATALYTIC CONVERTERS .

Disconnect the compressor electrical supply .

Unclamp the air conditioning pipe .

Remove the bolts (7a) .

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

Remove :

• the air cleaner
• THE INLET MANIFOLD

Unclamp :

• the expansion pipe (en C)
• the canister pipe
• the cooling pipe under the expansion chamber and in the wheel arch at (D)

Remove from their retaining clips :

• the canister pipe
• the expansion pipe

Remove :

• the connector (10)
• the expansion chamber and the expansion pipe
• the canister pipe

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

Remove :

• the bolts (11) on the right engine mount rod
• the torque reaction link
• the nut (12) on the flexible mount

Remove :

• the covers (14)
• the bolts (15)
• the two radiator brackets (13)

Move aside :

• the collars (16)

4HP20 AUTOMATIC GEARBOX

The hose (19), heat exchanger side on the gearbox .

NOTE : the cooling pipe (19) on the heat exchanger for the gearbox .

ALL MODELS

Remove :

• the hose (18) engine side
• the hose (17) (completely)
• the radiator

Remove :

• the (22) mounting bolts for the power steering high pressure pipe
• the bolt (21)
• the bolts (20)

Disconnect the connector (23) from the power steering circuit pressure sensor .

Do not dislodge the power steering pump from its bracket .

Remove :

• the battery protection plate (24)
• the battery mounting bolts
• the battery

Unclip the clip (25) .

Remove :

• the cardboard
• the bolts (26)
• the battery support

Unclip the accelerator cable (27) from the drum .

Disconnect :

• the connector (32)

4HP20 AUTOMATIC GEARBOX

Disconnect :

• the connectors (30) - (31)

ALL MODELS

Unclip the clip (29) .

Remove :

• the cold wall with the accelerator drum
• the control unit (28)

Disconnect in the correct order the three conectors (34) - (35) - (36) by pushing on the tab at (E) and turning the lock (33) .

Pass the connectors under the ecu bracket .

Disconnect the double relay (39) .

Unclip the clip (37) .

Expand the ecu bracket .

Open the clip (38) on the engine harness .

Disconnect the harness (41) .

Remove :

• the earth bolts (40) - (43)

Unclip the ventilation socket adaptor (42) from the air filter .

Remove :

• the air cleaner bracket (2 vis)

Clamp the air filter bracket in the wing inner panel .

Remove :

• the fuse box cover
• the supply harness of the fuse box, wires (44) - (45)

Expand the engine harness (41) on the engine .

Unhook the elbow (46) from the starter harness (47) .

Disconnect the starter harness from the main harness .

Vehicle with service battery :

• disconnect the maxi fuse and the dual battery ecu

Pass the starter harness under the air conditioning pipe and fold it down on the engine .

Move aside the bubble breaker with its unions .

Slacken the nut (48) .

Remove the 2 bolts .

Move aside :

• the control unit bracket

Separate hoses from heat exchanger (50) .

Disconnect the clutch control pipe At G .

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

4HP20 AUTOMATIC GEARBOX

Remove the 2 mounting bolts (54) on the gearbox control cable adjustment bracket .

Unclip the link (55) .

Separate control cable take-up support by turning rings (51) and (52) in direction indicated, push ring (53) back into place .

Move aside :

• the control cable

ML5T GEARBOX

By means of tool [4], unclip ball joints (57) (change) and (56) (selection) .

Remove the clips .

ALL MODELS

Attach engine to hoist [1] by means of lifting chains [2] .

Remove :

• the nut (62)
• the 2 bolts (60)
• engine mounting (58)
• the 4 bolts (59)
• the gearbox bracket (61)

Retrieve :

• heat shield of front precatalytic converter

Lift power train until power steering pump is level with front crossmember .

Release and clamp power steering pump to front crossmember F .

Remove the power unit from above .

3 - REFITTING

Replace :

• the exhaust clip
• metal seals of precatalytic converters
• the Nyloc nuts

ML5T GEARBOX

Replace :

• the final drive output lip seals using the tools [3]

ALL MODELS

Lower the power unit .

Position power steering pump in its support .

Position the power train .

Refit the right-hand engine mounting .

Position :

• the push rod
• the bolts (11)
• the nut (12)

Tighten :

• the bolts (11) to 5 da.Nm
• the nut (12) to 6 da.Nm

Refit the gearbox bracket .

Tighten the bolts (59) to 2,5 daN.m .

Position :

• the flexible mounting (60)
• the nut (62)
• the bolts (61)

Tighten :

• the nut (62) to 6,5 da.Nm
• the bolts (61) to 3 da.Nm

Lower the power train on to its mountings .

Replace heat shield of exhaust manifold .

Fit the bottom engine mounting torque reaction rod .

Tighten :

• the bolt (7) to 5 da.Nm

Position ventilation cowling (8) of lower shim .

Replace plastic rivet (9) .

REFIT THE DRIVE SHAFTS .

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

Refit the air conditioning compressor and its bracket .

Tighten the fasteners to 4 da.Nm .

Fit :

• the power steering pump
• the power steering pump pulley

Tighten the power steering pump securing bolts to 4 m.dan .

Continue the fitting operations in the reverse order to removal .

Refill :

• the gearbox (if necessary)
• the engine

FILL AND BLEED THE COOLING SYSTEM .