C6 - B1BG7GP0 - Removing - refitting : Engine/gearbox assembly Page 1 of 11

REMOVING - REFITTING : ENGINE/GEARBOX ASSEMBLY

ESSENTIAL : Observe the safety and cleanliness recommendations.

CAUTION : Before disconnecting the battery, partially open the door windows.

ESSENTIAL : If raising the vehicle on a lift, wheels hanging, remove the cap of the LDS fluid reservoir. Refit the
cap of the LDS fluid reservoir, once you have lowered the vehicle.

1. Recommended tools

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Figure : E5-P03TC
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[1] hub immobilising tool 6310-T.

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Figure : E5AP02WC

[2] pliers for removing and refitting hose clips 9029-T.

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Figure : B1BP032C
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[3] lifting bench with removable plate 5702-T.A.
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Figure : E5AP1GVC

[4a] Engine mounting with reversible tool 5704-T.

[4b] engine support 5704-T.

2. Removing

ESSENTIAL : Respect the safety and cleanliness recommendations that are specific to high pressure diesel
injection (HDi) engines.

Chock and lift the vehicle on a 2 column lift.

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CAUTION : Fit safety straps (see the relevant operations).

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Figure : B1BP3ESD
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Remove :
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 The engine cover

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 The sound-deadening under the engine

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CAUTION : Keep the luggage compartment lid open.

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Disconnect the battery.

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Drain the engine cooling circuit (see the relevant operation).

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Detach and move aside :

 The fuel supply pipe (1)
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 The fuel return pipe (2)

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 The hoses (8) and (9)

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 The radiator bottom hose ; Using tool [2]

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 The radiator lower hose ; Using tool [2]

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 The hose under the expansion bottle (10)

Disconnect the connectors "a".

Remove :
 The cover (4)
 The air filter (5) with the air flow sensor
 The air duct (3)
 The air duct (6)
 The air duct (7)

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Figure : B1BP3ETD C6
Unplug :
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 The connectors "b"

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 The connector "c"

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 The electrical harness (15)

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Detach and move aside :

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 The brake servo tube (11)

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 The hoses (16) and (17)

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Disconnect, unclip and move aside :

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 The electrical harness (18)

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 The earth wire on the gearbox

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Remove the engine ECU (12).

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Move aside the engine compartment fusebox (13).

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Remove ECU tray (14).

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Figure : B1BP3EUD C6
Remove the front bumper (see the relevant operation).
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Disconnect the connectors attached to the crossmember (19).

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Remove :
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 The cross beam (19)

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 The cross beam (20)

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Remove the front torque reaction rod (see the relevant operation).
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Figure : B1JP088D

Unscrew :

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 The front wheels

 The drive shafts (see the relevant operation)

Raise the vehicle.

Unplug :
 The connector at "d"
 The connector at "e"

Remove :
 The front wheels
 The drive shafts ; Using tool [1] (see the relevant operation)
 The spacer bar (25)
 The accessories drive belt (see the relevant operation)
 The air conditioning compressor fixings (21)

Suspend the air conditioning compressor (21) on the vehicle body.

Remove :
 The exhaust fasteners (26)
 The exhaust pipe and particle filter assembly (27) (see the relevant operation)
 The front sub-frame extensions (24) and (28)

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 The front sub-frame frame crossmember(22)

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 The vacuum tank (23)

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Uncouple the rear controlled rod (see the relevant operation).

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Place the vehicle at a height of 50 cm from the ground.
Centralise the lifting table 3 under the engine/gearbox assembly. C6
Lift the elevating platform [3].
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Figure : B1BP3EVC

Clamp the engine-gearbox assembly using tools [4a] and [4b].

N.B. : Place the tools [4b] on the edge of the oil sump. Place a tool [4a] on the rear fixing of the air conditioning
compressor.

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Figure : B1CP0HCC

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Place the engine support reversible tool [4a] in the right drive bearing.

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Make spacers to fix the engine support reversible tool [4a] :
 A spacer Ø 14 mm and length 40 mm at "g"
 2 spacers Ø 8 mm and length 6 mm at "f" and "h"
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Raise the lifting table [3] slightly to place the engine-gearbox assembly under stress.
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Figure : B1BP3EWC

Remove :
 The 4 bolts (30)
 The nut (31)
 The right-hand engine mounting (29)

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Figure : B1BP3EXD C6
Detach and move aside :
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 The gearbox control (33)

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 The pipe (35)

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 The tube (32)

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Remove :
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 The engine cooling radiator (see the relevant operation)

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 The bolts (34)

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Slowly lower the engine and gearbox assembly.

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Figure : B1BP3EYD C6
Support the engine cooling cassette (36) using a workshop hoist.
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Remove the upper and lower fixings of the engine cooling cassette (36).
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Tilt the engine cooling cassette .

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Move the engine-gearbox assembly forwards towards the front of the vehicle.
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Disconnect the starter supply at "j".

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Slowly lower the engine and gearbox assembly (using the lifting bench [3]).
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CAUTION : Ensure that there is no fouling between the engine-gearbox assembly and the body.
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Manoevre the engine-gearbox assembly to facilitate removal.

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Remove the engine-gearbox assembly from the front of the vehicle.

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Reposition the engine cooling cassette.

Refit the upper fixings of the cassette.
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3. Refitting
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Raise the vehicle.

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Position the vehicle at a height of 50 cm.

Support the engine cooling cassette using a workshop hoist.
Remove the upper fixings of the engine cooling cassette (36).
Tilt the engine cooling cassette (36).
Lift the elevating platform [3].

CAUTION : Ensure that there is no fouling between the engine-gearbox assembly and the body. Manoevre the
engine-gearbox assembly to facilitate its repositioning.

Position the engine-gearbox assembly facing its upper fixings.

Refit :
 The bolts (34) : Tighten to 6 ± 0,6 daN.m
 The engine mounting (29)
 The bolts (30) : Tighten to 6 ± 0,6 daN.m
 The nut (31) : Tighten to 6,5 ± 0,6 daN.m

Withdraw the lifting bench [3] from under the vehicle.

Refit the engine cooling radiator (see the relevant operation).
Position and couple up :

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 The tube (32)

 The pipe (35)
 The gearbox control (33)
 The front sub-frame frame crossmember(22)
 The vacuum tank (23)
 The front sub-frame extensions (24) and (28)
 The exhaust pipe and particle filter assembly (27) (see the relevant operation)
 The clips (26)

Recouple the rear controlled rod (see the relevant operation).

Position the air conditioning compressor (21).
Reconnect the connectors "d", "e".
Refit :
 The air conditioning compressor fixings (21) : Tighten to 2,3 ± 0,3 daN.m
 The accessories drive belt (see the relevant operation)
 The spacer bar (25)
 The drive shafts (see the relevant operation)
 The front wheels

Place the vehicle on the ground.

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Tighten :

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 The drive shafts (see the relevant operation)

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 The front wheels : Tighten to 9 ± 0,5 daN.m

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Refit :
 The front piloted torque reaction rod C6
 The cross beam (20)
 The cross beam (19)
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Reconnect the connectors attached to the crossmember (19).

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Refit the ECU tray (14).

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Position the engine compartment fuse box (13).

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Refit the engine ECU (12).

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Position and reconnect :

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 The electrical harness (18)

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 The earth wire on the gearbox

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Position and couple up :

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 The hoses (16) and (17)

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 The brake servo tube (11)

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Connect :
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 The electrical harness (15)

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 The connectors "b"

 The connector "c"

Refit :
 The air duct (7)
 The air duct (6)
 The air duct (3)
 The air filter (5) with the air flow sensor
 The cover (4)

Connect the connectors "a".

Position and couple up :
 The hose under the expansion bottle (10)
 The radiator top hose
 The engine cooling radiator lower hose
 The venting hoses (8) and (9)
 The fuel return pipe (2)
 The fuel supply pipe (1)

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Fill and bleed the cooling system (see the relevant operation).
Perform the following operations :
 Check the brake fluid level
 Check the LDS fluid level

Refit the engine style cover .

Check the operation of the air conditioning.
Carry out :
 A road test
 A reading of the diagnostic memories

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