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Peugeot VTi (Gen I) - Engine

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1K views377 pages

Peugeot VTi (Gen I) - Engine

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lyes
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208-BIBBOTAIPO- Technical nto Engine al capacities TECHNICAL NOTE : ENGINE OIL CAPACITIES CAUTION : Always check the oil level using the dipstick ll change interval : Refer to the maintenance schedule. N.B. : Values given as an indication. 1. Petrol engines 1.1. Engines types EW EPGCDTM - EPSCDTMD - EPECDTX [Engine type EW7A- __JEW7J4-EW10J4-EWT0D -EWT2i4-_ JEW10V4i Ewioa_|ew12a [Oil capacity without replacement ofthe filer cartridge 4.75 lies [4 lives [Sires [Gil capacity with replacement ofthe fier cartridge [6 litres 4.25 hires 5.25 tree [Capacity beiween minimum and maximum on the oll [1.7 lite H.7 tire HS tire leauge 1.2. Engines types EP [Engine type EPS - EPSC - EPO - EPOG - EP6CB - EPGCM - EP6DT - EPODTS - EPGCDT- (Oil capacity without replacement of the [4 litres: liter cartridge [Oil capacity with replacement of the filter [4,25 litres cartridge (Capacity between minimum and 12 litre lmaximum on the oil gauge 1.3. 4A92 - 4B11 - 4B12 engines waoz [B11 [ai2 (Oil capacity without replacement of the filter cartridge [4 lires [4:25 titres) [Oil capacity with replacement of the filter cartridge la.2 tres], litres|4,5 lives (Capacity between minimum and maximum on the oll gauge| 1.4. Engines types EB [Engine type E60 - £82 -EB2M (Oil capacity without replacement of the filter cartridge |S itres [Oil capacity with replacement of the filter cartridge [3.5 litres [Capacity between minimum and maximum on the oll gauge[t litre 1.5. Engines types ECS [Engine type lec 5m FF[EC su) (Oil capacity without replacement of the filer cartridge [8 litres [oil capacity with replacement of the filter cartridge [3.25 litres “ 208 BIBBOTAIPO- Technical nto Engine al capacities |Capacity betwoen minimum and maximum on the oil gauge|1,5 litre 1.6. 384F engine [Engine type Baar [Oil capacity without replacement of the filter cartridge [2,75 litres| (Oil capacity with replacement of the filter cartridge i titres: [Capacity between minimum and maximum on the oll gauge|t litre 41.7. Engines types ES9 [Engine type lesouas [ESoA-Esou4 [ESoA [Engine legislative type. IxFX___[xFV- XFU- XFWIXFX [Oil capacity without replacement of the filter cartridge __[pitres [4,6 litres [4,25 titres] [Oil capacity with replacement of the filter cartridge 5.25 ltres|4,75 titres las tres [Capacity between minimum and maximum on the oll gauge)? lites, 1.8. ET3J4 engine [Engine type ET3v4 (Oil capacity without replacement of the filter cartridge [2,75 itres| [Oil capacity with replacement of the filler cartridge i tres: [Capacity between minimum and maximum on the oll gauge|1.5 litre 1.9. Engines types TU [Engine type [rut - Tus[rus - TusM| (Oil capacity without replacement of the filer cartridge [2,75 litres [3 litres [Oil capacity with replacement of the filter cartridge bites [3.25 tires (Capacity between minimum and maximum on the oil gauge|1,5 litre [1.5 lire 2. Diesel engines 2.1, Engines types DV [Engine type [DvaTD- [Vac - DV6A - DV6AU - DV6B - DVEBU -DV6TED4-DV6C- JDVEUTED. IDvaTED |DV6CM - DV6DTED - DV6DBM - DV6ETED - DV6ETEDM [Oil capacity without replacement[3,25 litres [3,25 litres la.75 tires lof the filter cartridge [Oil capacity with replacement of [3,75 litres [3,75 litres tres the filter cartridge [Capacity between minimum and |i, litre [1,5 litre Hire |maximum on the oil gauge 2.2. Engines types DW10 [Engine type Dw10TD - DW1DATED4[DW10BTED4 - DW10UTEDA| (Oil capacity without replacement of the filter cartridge [4,5 litres I ltrs [oil capacity with replacement of the filter cartridge [4.75 litres [5,25 titres: [Capacity between minimum and maximum on the oil gauge| 1.4 litre [2 itres [Engine type bwiocteDa [owrocTeDs 208.-BIBBOTAQPO- Technical nto Engine al capacities [RPO number Faimpippagacememama. oan fas PAnrseFfom|t 1918 ipstick fancie-Yettow ft ae [Engine type lowaocTED4 [Engine legislative ype IRHO-RHE-RHH [Oi capacity without replacement ofthe filer cartridge _[6,25itres _[a,75 tres [Oil capacity with replacement ofthe filer cartridge [55itres [5 tres [Capacity between minimum and maximum on the oll gauge|1,7 lire Fre [Engine type |DW10CD - DW10CE|DW10DTED4| [Engine legislative wpe [Anz - AHY [RAB [Oi capacity without replacement ofthe filer caridge [4,76 lires loll capacity with replacement ofthe fiter cartridge sires [Capacity between minimum and maximum on the oi gauge lire 2.3, Engines types DW12 [Engine type Jow12c - DW128TED4 - DW12UTED - lowi2TeD lowi2MTEDa (Oil capacity without replacement of the filter cartridge [6 litres [6.5 titres [Oil capacity with replacement of the filter cartridge [5,25 litres [4.75 litres (Capacity between minimum and maximum onthe oil [1,7 litre lgauge 2.4, F30DTE engine Engine type F30DTE EURO 4]EURO 5 (Oil capacity without replacement of the filter cartridge [7,6 litres|8 Itres [Oil capacity with replacement of the filler cartridge [2.6 hives|9 titres (Capacity between minimum and maximum on the oll gauge|t litre _ [1 litre 2.5. DT17ted4 engine Engine type DT17TED4 [Designation By gravity[By suction] [Oil capacity without replacement of the filter cartridge [5.25 litres [5,5 litres [Oil capacity with replacement of the filter cartridge [5.5iitres [5,75 litres (Capacity between minimum and maximum on the oll gauge|1,75 litre [1,75 litre 2.6. Engines types F28 Engine type F28D - F28DT - F28DTGR - F280 TSE [Designation [e140.63 - 6140.43-[8140.23 - 8140.43 S| (Oil capacity without replacement of the filer cartridge [6 lives, [7 ttres [Oil capacity with replacement of the filter cartridge [a7 fitres [57 litres [Capacity between minimum and maximum on the oll gauge|- [ 2.7. 4N13 engine [Engine type ENTE 208.-BIBBOTAPO- Technical nto: Engine al capacities [GiTeapaciy without replacemep ga anaes a BA [Siteapectty 2.8. DW8 engine Engine type DW8 [Designation [Without air conditioning]With air conditioning] (Oil capacity without replacement of the filter cartridge [4,5 litres [4,25 litres: [Oil capacity with replacement of the filter cartridge [4,75 litres [4.6 hires: [Capacity between minimum and maximum on the oll gauge|1,5 litre 2.9, DT20C engine Engine type DT20C [Designation By gravity[By suction] (Oil capacity without replacement of the fiter cartridge [6.1 litres [6,96 litres [Oil capacity with replacement of the filter cartridge [6.25 litres [65 litres (Capacity between minimum and maximum on the oil gauge|1,75 litre 2.10. 2,3 SOFIM engine [Engine type [2,3 SOFIM| (Oil capacity without replacement of the filter cartridge [5,9 litres (Oil capacity with replacement of the filter cartridge [6.5 litres [Capacity between minimum and maximum on the oll gauge|- 2.11, PUMA 2.2 DTE engine Engine type PUMA 2.2 DTE EURO [EUROS [Engine legislative type JHV/sHUSHM|sHG/aHH|H (Oil capacity without replacement of the fiter cartridge [6.75 fires [5,9 itres [Oil capacity with replacement of the filter cartridge [6 litres 2 litres (Capacity between minimum and maximum on the oil gauge|1,5 litre 1,5 litre 2.12. F13DTE engine [Engine type FAs0Te| (Oil capacity without replacement of the filter cartridge |B lives, (Oil capacity with replacement of the filter cartridge [2.2 fires [Capacity between minimum and maximum on the oll gauge|- 1. Engine code 208 BIBBOIAAPD- Tectnical note: General engine information TECHNICAL NOTE : GENERAL ENGINE INFORMATION Figure: ETABOTLD (1) : First 2 characters of the engine code. FFirst 2 charactersfengine [Commercial designation (oF fpeaF [1ortav zm lee [10ivTl IHF fur [nat lam les2 [1.21 tevvTl ikF- rus [at Ike- kr fers [1.4 tev INF Tus [1.6 16v Ine- INF lecs_[1e1t6v INK lance [161 tev laF- asi1 [2.01 16v. ISF- lapi2 [2.4 tev lar eps [1.4 vm tev ler eps [1evTi tev [1.6 THP 16V, ler lew7__[18itev. IRF lewio [2.0116v 16 206 BIBBOIAAPD- TecInical note: General engine information br lewr2_[a2itev kr lesa |veso1aav lex Jove [1.4 1HDi lon: love [1,01HDi om lanis [1,81 HDF IRE Jowi0 [2.0HDi tov IaH Jowi2 [221i tov |P22DTE|2.2 HDI (Puma) engine type| Fr [F20DT [8.0 HDi (Sofim engine type) lH lori? _fa.7 HDi 2av e Jor20_[.0HDI24v 2. petrol engines pearfesofrur [rus [Engine legislative ype [CEA [2mz|HEX” HEVIKFX [KEV JK@D/ KOF [KOE [KFT [KFWIKFS [Capacity (ce) Jove [aoe |rr24 [1360 [Bore (mm) (71 72 75 [Travel (mm) 84 [69 77 [Maximum power : (KW EEC) [50_ 44 55 [54 [53 54 [55 lEngine speed al max. power (p.m. [6000 [a000)5500 Js400|5300 _|sa00|5200)s600 IMaximum torque (daNmEec) os 9s fa [ina[na he [Engine speed at max. torque (-p:m,}3600)3000)3300 _[s40o}2s00ja400 [3300 fs4o0)ze09 Jes [e62 [eo2 mrus lEngine legislative type IKFUJHMz|aMy_[NFRINFZINGAINFV INFV NFU NFS [Cubic capacity (co) faeo}i109 —_*(1587 [Bore (mm) rs ire Travel (mm) 7 7 Maximum power: (KW EEC) es 2 les fos [rs —‘|ro_o0_o [Engine speed at max. power (1.p.m.) [5250] [5500 _|5800/5600 |5700}5800|6500] [Maximum torque : (daNm EEC) 13,3 at 13,2 [13,5 [14,2 [13,5 |14,7 [14,3 [Engine speed at max. torque (¢.p.m.)}3250)2750|2000 [2500[3000 _[4000)3000|4000|3759 [aac2fae11 [412 __ [Epa EPac [Engine legislative type lnkz Jarz JAFY [SFz/ SFY|arS/ BF PlEFR| Cubic capacity ( cc) 1590 1998 [2359 11397, [Bore (mm) 75, [88 [77 [Travel (mm) [90 97, [75 [Maximum power : (KW EEC) les fi13 [125 [ro 2 [Engine speed at max. power (rp.m.)|6000 [Maximum torque : (daNm EEC) 15,4 19.8 [23,2 13,6 [Engine speed at max. torque (r.p:m_)}4000 4209)a2s0]4t00 [4000 [EPA/ EPEC IEPeDT/ EP6CDT lEPaDTS [Engine legislative type l5rK [SFP/ SFJ5FW/ SS) SFL|SFT [SFX SFY SF4/ SFE[SFV/ SFRISFMISFY [SFFISFD [Capacity (co) 98 [Bore (mm) 7 [Travel (mm) (85, 206- BIBBOIAAPO- Tectnical note: General engine information IMaximum power : (KW EEC) [72 es es [103 [110 [its [120 jr28 |rag|is2. [Engine speed at max. power (r.p.m.)[6000|5200_ [6000 [s800)6000 [Maximum torque (daNmEeC) [162/16 fea prs [Engine speed at max. torque (r.p.m_)}3500)4250 1400 '1600)2000 [EPeCDTS[EPaCDTX[EW7A_[EWIOA [Engine legislative type Fu sFU__|orz [ery [RFN]RFHRFL [Capacity (co) 1598 [rrag|i7a9lioo7 [Bore (mm) lr 2.7 2.7 [os [Travel (mm) bs a1.4 [61.4 [aa [Maximum power = (KW EEG) as fra7___[as_fo2_|100 [ios [Engine speed at max. power (r.p.m.)[6000 [5800 __[5500]6000 [Maximumtorque(daNmeec) 55 7s [ie fir [is fie [20 [Engine speed at max. torque (rp.m.jfi600 [1700 __[4o00}3750}+100]4000 Ewi2udeso Jecs lEngine legislative type bez [xew)xeviNer (Capacity (co) e230 |aove [1587] [Bore (ram) es er_—srass [Travel (mm) a [Maximum power : (KW EEC) 16 [150 [165 [a5 [Engine speed at max. power (rp.m)|5650 [6000 [6000] [Maximum torque: (daNmEeC) 24,7 28.5 [20 [16 [Engine speed at max. torque (rp.m)fs900 [3750 [4000] 3. diesel engines pve pve Engine legataive ype janr[arons/ ener aurlpnz BAY jonwfoany on[onT/aaZ[Bny [Capacity (ce) isos 560 [Bore (mm) [73 75, [Travel (mm) 82, (88,3 [Maximum power : (KW EEC) [40 [50 66 [55 (94 |73 [Engine speed at nox. power rpm 4000 loo s7a0 Maximum torque: (daNm EEC) fis [ie [ie fe bo }sfes bo Bsa [Engine speed at max. torque (r.p.m.)/1750_ }2000]1750]1750|1500 1750 pve we Engine epee ype lH aravJonFTanE[prO [brow OnVoNPr enufonvT nz[oH [ono wuz Woy [Capacity (cc) 1560 1868 Bore (wm bs lez Havel (rm) as es Ivaximum power: (WEES) [ee a a [Engine speed at max. power (r.p.m.) }4000_ [4600 [Maximum torque : (daNm EEC) 18 [21,5 18 [215 [23 24 27 |25,4/12,5 [Engine speed at max. toraue (pm) [1600 i750 fs00|1750 —f2so0 pwio Engine legislative ype IRHv[RHY AR [RASY RMJRaT[RHG” RRR PZ /RPURHRY RH 208 BIBBOIAAPD- Tectnical note: General engine information \Capacity (co) 1997 [Bore (mm) les. [Travel (mm) lee [Maximum power : (KW EEC) lez_[os_[r2_ [vo leo [ee fea [oa Troofioo [Engine speed at max. power (r.p.m.) [4000 Maximum torque :(daNmEEC) — [19.2)20,5[26 [25 a7 po be fe br fe [Engine speed at max. torque (rp.m.)|i900__[1500|1750 j2000 ow10 lowi2 [Engine legislative type IRHF [RHE |RHHJRHC|4HW [HN 4HK[GHP [AHR [4H [Capacity (ce) foo7 [2179 [Bore (mm) les. les [Travel (mm) lee lee [Maximum power : (KW EEC) fios fito fizo fea [tas Yrzo [r20 [ras [Engine speed at max. power (r.p.m.) [ao00)3750)3850[5750/4000 [Maximum torque : (daNm EEC) po fea bo bape B7 [40 [7 [Engine speed at max. torque (r.p.m.) [2000 [17502000 /1500|1750|1509] Jowi2 |ori7prz0 [pzanTe [Engine legislative type. las Janie Junz [xey [xez [aHvs AlaHUr B]4HM| [Capacity (co) l2i79 [2720 [200a|2003/2198 [Bore (mm) les. ler [ea lee: [Travel (mm) lee lee [oo [o4.6 [Maximum power : (KW EEC) fi25 [150 liz7 [vs [ra fas es [Engine speed at max. power (r.p.m.) [4o00}3500f4000 [800 [2900 [3500 [Maximum torque : (daNm EEC) lao fas faa [50 [a5 [25 (a2 [Engine speed at max. torque (r.p.m,) fr7s0jz009[1900 _[r600]1500 [2000 Fa00T ania [Engine legislative type [Ficeoss1D|6Hz [Capacity (co) feos (1798. [Bore (mm) lee les [Travel (mm) loa [aa.1 [Maximum power : (KW EEC) 145 htt0 [Engine speed at max. power (ro.m) [3500 [4000 [Maximum torque (daNm EEC) [40 0 [Engine speed at max. torque (rpm.[i700 [2000 4, Electric motors Jlonic-2ero_|Partner/Beriingo) enturi [Engine legislative type lexz E [Engine type [Triple-phase synchro motor [Maximum power: (KW EEC) las 2 (Continuous power, bbs E [Engine speed at max. power (r.p.m.)|2500 to 8000 mpm [Maximum torque: (daNmEEC) [16 [Engine speed at max. torque (r.p.m.)]0 to 2000 rpm _ 208 BIBBOIAAPD- Tectnical note: General engine information 208- BIBBOTABPO- Toctrical note: Avcllary drive ba TECHNICAL NOTE : ANCILLARY DRIVE BELT 1. Flexible ancillary drive belt ESSENTIAL : Before removal and for any future reuse of the removed belt, the engine must be at ambient temperature (below 30°C) ; In all other cases : Replace the flexible ancillary drive belt . CAUTION : Mark the direction of rotation of the ancillary drive belt before removing it. CAUTION : If re-using the existing accessories drive belt, refit it in the correct fiting direction, CAUTION : Check that the rollers turn freely (no play and no tightness). 2. Visual check Check that the timing belt is free of cracks and traces of ol Check the absence of oil leaks (crankshaft and camshaft sealing rings). Check the absence of coolant fluid leaks (Coolant pump). Check that the track of the engine speed sensor target is not distorted or scratched, N.B. : Replace any defective parts. 3. Petrol engines 3.1. 384F engine Figure: B1BBTE8D all models. (1) Air conditioning compressor (according to equipment). 3.2. TU1/TUS/TUS/ETS engines Figure: 61887690 Without power steering and without air concitioning. Figure: B1BBTEAD Without air conditioning / With driven power steering pump. Figure B78B/E5D 208- BIBBOTABPO- Toctrical note: Avcllary drive ba With air conditioning and without power steering. Figure: B1BB7E0D With air conditioning / With driven power steering pump (Manual tension roller) Figure: B18B7EDD With air conditioning / With driven power steering pump (Dynamic roller tensioner ). Figure: B16B7EED With air conditioning / Power steering electric pump assembly (Dynamic roller tensioner ). 3.3, EBO/EB2 engines Figure B1BBILTD With air conditioning, Figure: B188iLUD Without air conditioning. 3.4, EP3/EP6 engines Figure = B1881EFD all models. (1) Air conditioning compressor (according to equipment). 3.5. ECS engine Figure BBBILVD Without air conditioning. Figure B1887LWD With air conditioning. 208- BIBBOTABPO- Toctrical note: Avcllary drive ba 3.6. EW7/EW10/EW12 engines Figure: B1887E6D Without alr conditioning / With driven power steering pump. Figure: B18B7EHD With air conditioning / With driven power steering pump. Figure BBBTEID With air conditioning / Power steering electric pump assembly (1): Air conditioning compressor (according to equipment). 3.7. 4492 engine Figure: BiBBT1Z0 all models. 3.8. 4B11/4B12 engines Figure: B1BBIEID all modols. 3.9. ES9 engine Figure: B1BBTEKD all models. 4. diesel engines 4.1, DV4IDV6 engine Figure: BIBBIELD Without air conditioning. 208- BIBBOTABPO- Toctrical note: Avcllary drive ba Figure: B18BEMD With air conditioning. Figure: B1BB7END Without air conditioning / With driven power steering pump. Figure: B1BB7E0D With air conditioning / With driven power steering pump. Figure: B18BEPD With air conditioning/Power steering electric pump assembly / Stop and start. 4.2. DW8/DW10/DW12 engines Figure B1BBIEGD Without power steering and without air conditioning, Figure: B1BBIESD Without air conditioning / With driven power steering pump. Figure: B188E7D With air conditioning and without power steering. Figure: B18BiEUD With air conditioning / With driven power steering pump. Figure: B1BBIEVD With air conditioning / Power steering electric pump assembly 208- BIBBOTABPO- Toctrical note: Avcllary drive ba Figure: BBBIEWD With air conditioning / Power steering electric pump assembly Figure: B1BB1EXD With air conditioning / Power steering electric pump assembly / Hybrid Figure: BBBTTED With air conditioning / Power steering electric pump assembly 4.3, DT17/DT20 engines Figure: BBB TED all models. 4.4, 4N13 engine Figure: 6188700 all models. 4.5. P22DTE engine Figure: B18B1E2D Without air conditioning. Figure: B1BB;F0D With air conditioning, 4.6. F30DT engine Figure B1BBFID all models. 208- B1BBO1SSPO.-Tightsring torques : EP engines (indrectirjacton) TIGHTENING TORQUES : EP ENGINES (INDIRECT INJECTION) 1. Engine top 1.1. Cylinder head CAUTION : Follow the tightening sequence. Figure: B1BB10PD [Reference[Designation [Tightening torques Ky) bolts (Cylinder head cover) (*) [Pre-tighten to 0,2 daNm [Tighten to 1 da.Nm (2) bolts (Cylinder head) (*) [Pre-tighten to 3 daNm_ [Angular tightening to 90°| [Angular tightening to 00°| 3) lpolts (Coolant outlet housing ) ft dam ay foolts ( vacuum pump) [0.9 daNm (5) [Studs (Exhaust manifold) [1.5 daNm Ko) lootts (Cylinder head / Cylinder block ) *)[Pre-tighten to 1,5 daNm [Angular tightening to 90°| [Angular tightening to 90° [Spark plugs [2.3 daNm 8) [bolts (Cylinder head / Cylinder black ) (*)|2,5 daNm_ [Angular tightening to 30°| [C) Follow the tightening sequence 208 BIBBOISSPO- Tring torques :EP eres ntroatirecon) 1.2. Order of tightening : Cylinder head cover Figwe:BBB1000 (1) Cylinder head cover securing bolt. 1.3. Order of tightening : Cylinder head Figure: 61887180 (2) Cylinder head bots. 208 - B1BBO1SSPO - Tightening torques : EP engines ( indirect injection) 1.4. Supply : Air inlet manifold ; Throttle butterfly housing 12 13 Figure B1BB0SUD [Reference[Designation [Tightening torques| () [nut (Air infet manifold) (7) [2 daNm (10) ___[Studs (Air inlet manifold) [1,5 daNm (11) bolts (Throttle butterfly housing /Air inlet manifold) (New) [1 daNm [bolts (Throttle butterfly housing / Air inlet manifold) (Re-used)|0,8 daNm (12) bolts ( support / Air inlot manifold) [0.8 daNm (13) ootts ( support / Cylinder block ) [2 daNm (14) bolts (Air pressure sensor) [1 dam (C) Follow the tightening sequence 1.5. Order of tightening : Air inlet manifold 208- B1BBO1SSPO.-Tightsring torques : EP engines (indrectirjacton) Figure: 81881170 (9) Mounting nut : Air inlet manifold. 2. Under engine CAUTION : Follow the tightening sequence. 2.1. Cylinder block 208- B1BBO1SSPO.-Tightsring torques : EP engines (indrectirjacton) Figure: 81880SHD [Reference[Designation [Tightening torques a loots (Water pump pulley ) [0.8 dann 2) loots (Coolant pump / Gylinder block ) [0.9 dam (3) [Oil gallery caps on cylinder block 5 daNm la loots (Crankshaft main bearing cap casting) (90.9 dam () foots (oi! pump) () [Pre-tighten to 1 dan [Tightening to 2,5 m.daN ( [rain plug Is dani im [bots (Lower oll sump) 1.2 dan () loots (Pinion of the oil pump) [0.5 danm ular tightening to 90" 9 bots (Antifoam plate) fda (110) batts (Crankshaft bearing) (*) [Pre-tighten to 3 daNm [Angular tightening to 150" (a7) [knock sensor [2 dan [C) Follow the tightening sequence 2.2. Order of tightening : oil pump Figwe: 81887180 (8) Oil pump bolt 2.3. Order of tightening : Crankshaft main bearing cap casting 208- B1BBO1SSPO.-Tightsring torques : EP engines (indrectirjacton) 229095 . Figure: B10M03HD (4) Crankshaft bearing cap housing fixing screws, (10) Crankshaft beating cap fixing sorews, 2.4, Reciprocating gear Figure = B18805YD [Reference] [Designation [Tightening torques lazy lpolts (Accessories drive pulley) 2.8 daNm anu 208- B1BBO1ESPO.-Tightsring torques : EP engines (inrectirjacton) (13) __Jootts (Crankshaft gear ) [Tightening to 5 m.daN [Angular tightening to 180°| (14) [Engine speed sensor [0.5 daNm (15) alts (Engine flywheel) (°) [Pre-tighten to 0,8 daNm [Tightening to 3 m.daN [Angular tightening to 90° lbolts (Automatic gearbox panel) (*)[Pre-tighten to 0,8 daNm [Tightening to 3 m.daN gular tightening to 90° (16) bolts (Big end caps) [Pre-tighten to 0,5 daNm [Tightening to 1,5 mdaN [Angular tightening to 130°| [C) Follow the tightening sequence 2.5. Order of tightening - Engine flywheel / Automatic gearbox panel Figure: B1BBOSZD (18) Flywheal bolts 3. Lubrication 3.1. 1st assembly m4 208- B1BBO1SSPO.-Tightsring torques : EP engines (indrectirjacton) Figure: B18B0T0D [Reference]Designation [Tightening torques] io [Engine oil temperature and level sensor_[2.7 dam (2 [Oi pressure sensor (on the cylinder head) 2 danm ( [oi iter cover [2.5 danm l@ foots (Oi fer support / Cylinder block) [1 dat 3.2. 2nd assembly Figure: BiFBOIaD IReference[Designation [Tightening torques| ay [Engine oil temperature and level sensor]2,7 daNm (2) [Oil pressure sensor [2 dann (a) [Oil fiter cover [2.5 daNm ka bolts (Oil fiter support / Cylinder block )|1 daNim 4, Timing gear CAUTION : Follow the tightening sequence. 4.1. Cams ishafts an 208- B1BBO1SSPO.-Tightsring torques : EP engines (indrectirjacton) Figure: 81887190 [Reference[Designation [Tightening torques io [Variabe it spring bot [i cannm (2) [Sider botts (*) [Pre-tightening to 0,5 da.Nm JAnguler slackening of 90" [Tighten to 1 da.Nm @ bolts (Main bearings of the eccentric shaft / Induction camshaft) ()|1 daNm. (a loots (Inlet camshaft main bearing caps) (*) [i Gam BY bots (Exhaust camshaft main bearing caps) () [i dann (6) [Eccentric shaft target fixing bolt lo.9 dan [() Follow the tightening sequence 4.2, Order of tightening : Sliders a 208- B1BBO1SSPO.-Tightsring torques : EP engines (indrectirjacton) of yy: My | YY ds Figure: B1EB000 (2) Slider bolts. 4.3. Order of tightening : Main bearings of the eccentric shaft/Induction camshaft Figure: B1EBOOND (3) Bolts of the main bearings of the eccentric shaft/Induction camshaft. 4.4, Order of tightening : Inlet camshaft main bearing caps 208- B1BBO1SSPO.-Tightsring torques : EP engines (indrectirjacton) Figur B1EBOOKD (4) Inlet camshaft main bearing cap bolts. 4.5. Order of tightening : Exhaust camshaft main bearing caps Figure = B1EBOOLD (5) Exhaust camshaft main bearing cap bolts. 4.6. Timing controls cd 208- B1BBO1SSPO.-Tightsring torques : EP engines (indrectirjacton) Figure: B1BB70RD [Reterence[Designation [Tightening torques jm loots (Variable timing actuator) () fo.8 dani (@ [Position sensor (Eccentric shat) 0.8 danm ‘o) ots (intet gear) [Tightening to 2 m.dan [Angular tightening to 180" (710) bots (Exhaust geary [Tightening to 2 m.daN [Angular tightening to 180" [()___ [Top fixing screw = Fixed guide 2.5 danm (112) [Bottom fixing screw : Guides 24 datum (13) bolts (Piloting electrovalves ) (Timing gear) _ [0,9 daNm (‘14) [Cylinder reference sensor (inlet camshaft) [0.8 daNm [Cylinder reference sensor (exhaust camshaft|0.8 dam (5) [Timing chain tensioner [8.5 dam [() Follow the tightening sequence 4.7. Order of tightening : Variable lift actuator Figure: Bi8BiL8D (7) Variable lift actuator screws, 5. Fuel supply Figure: B1BBOTED waa 208- B1BBOIESPO.-Tightring torques : EP engines (inrectirjacton) RReference[Designation [Tightening torques] (1), [bolts (Fuel high pressure common injection rail )]0,8 daNm_ 6. Alternator Figure YABOGED RReference[Designation Fightening torques] Kt) [bolts (Coolant pump friction wheel) |0.8 daNm (2) nut (Altemator supply hamess) [1,6 daNm (3) [bolts (Alternator / Roller tensioner )|2 daNm 7. Starter Faure: DY@B00CD RReference[Designation [Tightening torques| (4) foots (Starten [2 daNm (5), [nut (Starter supply hamess)|1,6 daNm 8. Air conditioning compressor Figure CSHB0000 [Reference[Designation Tightening torques| 194 208- B1BBO1ESPO.-Tightring torques : EP engines (inrectirjacton) eo footts (support / Cylinder block ) fz dam a bolts (Air conditioning compressor / support )[2.4 daNm (@ INuts ( support / Cylinder block) [2 dam wie 208 B1BBOTTRPO- Checking and ajusting values : Engines typos EPS EP2O - EP6 EPEC - EPECB - EPEC M CHECKING AND ADJUSTING VALUES : ENGINES TYPES EP3 - EP3C - EP6 - EP6C - EP6CB - EP6C M 1. Foreword 4.1. Units of pressure 41.4.4 Units of pressure in bars. NB. : One bar has the advantage of being close tothe average atmospheric pressure at sea level 41.1.2 Unit of pressure in millimetres of mercury (symbol: mmHg) or Torr (symbok Torr). Unit for measuring pressure initially defined as the pressure exerted at 0°C by a 1 millimetre column of mercury, and later indexed to atmospheric pressure, N.B. : The values of pressure indicated in the tables below are in relative pressure. N.B. : Relative pressure is equal to absolute pressure minus atmospheric pressure. 1.2. Units of tension ‘The SEEM unit measures by deflection of the static tension of the belt, by deforming a portion of its length. 2. General engine information 2.1. Engines types EP3 - EP6 [Engine type ers EPe [Engine legislative type FS [pF [Cubic capacity 397 cc [1598 ce FFuer [Super unleaded 96 RON) [Maximum power [row [a8 KW [Engine speed at maximum power 6000 rpm _[8000 rem [Maximum torque {13 daNm [16 daNm [Engine speed at maximum torque|4000 rpm [4250 rem 2.2. Engines types EP3C - EP6C - EP6C M [Engine type lEPsclEPsclerec _|EPecM [Engine legislative type. FR [erp [prs [SFS (Cubic capacity 1397 [1598 ce Fuel [Super unleaded 95 RON. (Maximum power. [72 kw]70 KW]8s KW. [Engine speed at maximum power|6000 rpm [6000 rpm[5860 rpm (*) Maximum torque 13.6daNm_|16 daNm [Engine speed at maximum torque|4000 rpm [4250 rpm (0) Russia version 2.3. EP6 CB engine type [Engine type EPS cB) 18 208 B1BBOTTRPO- Checking and ajusting values : Engines types EP3- EPO - EP6 EPEC - EPECB - EPEC M lEngine legislative type ls [Cubic capacity 1598 cc [Fuel [Super unleaded 95 RON) IMaximum power [ro kW [Engine speed at maximum power [6000 rpm [Maximum torque 15,2 daNm| [Engine speed at maximum torquel3600 rpm (() Decalibrated engine 3. Sparking plugs [Engine ype Plus [Electrode gap leP3.ePac IBERU (Maliple elctrodos)[1 = 0.05 mm |EP3-EP3C (Hot countries)|BERU (One electrode) 0,95 + 0,1 mm lEPo-EPEC [BOSCH [0.96 # 0.05 mm 4. Oil capacity [aftr oi change, without replacement of fiter [Altres [after oi change, with replacement of fiter 6.25 ves [Difference between minimum and maximum on the gaugal}.2 lire ll change interval : Refer to the maintenance schedule. ‘CAUTION : Always check the oil level using the dipstick. 5. Oil pressure 5.1, Engines types EP3 - EP6 lll pressure is checked with the engine hot after checking the oil level. ll tamperature fixed at 80 °C. [Engine speed)|Pressure {1000 rpm [2+ 0,3 bar 2000 pm [3.2 + 0.3 bar| [4000 rpm 3.2 + 0.3 bar| 5.2. Engines types EP3C - EP6C - EP6CB [Engine speed)Pressure IDLING [47 £0.3bar| 1000rpm [1.80.3 bar| [2000 rpm _ [2+ 0,3 bar 3000 mpm [2,6 + 0,3 bar| [4000 rpm [3,5 + 0,3 bar| CAUTION : Carry out work on the engine ifthe oil pressure values are below those in the table. 6. Ancillary drive belt 208 B1BBOTTRPO- Checking and ajusting values : Engines types EPS EPO - EP6 EPEC - EPECB - EPEC M lequipment[Beit tension [Ail types [By dynamic roller tensioner 7. Timing chain fequipmeni [Chain tension [Ailtypes [By chain tensioner| 8. Cylinder head bolts CAUTION : Always replace cylinder head bolts and washers. 9. Pressure, engine end of compression Measure the pressure at the end of compression, in order, on cylinders 1, 2, 3 and 4. N.B. : The difference in pressure between 2 cylinders must not exceed 5 bars. CAUTION : Always search for the origins of fault(s), where the values measured are found to be significantly out. 208- BIBBOI8HPO- Iereation- Data: Under enna EP engin inretinjacton) IDENTIFICATION - DATA : UNDER ENGINE - EP ENGINE ( INDIRECT INJECTION) 1. Cylinder block assembly Figure = 81080360 Identification : Cylinders Components['a" fo" ['o* fa" PsA IN-a[Nra}Ne2fiver "e' Flywheel side. “F Timing gear side. FFlatnass of the cylinder block (close ta the cylinder head)]0,025 mm [Diameter of the cylinders: [77 (0; + 0,016) mm [Liner protrusion [o+ 0.3mm The oylinder block is non-repairable. 1.4. Cylinder block 208- BIBBOI8HPO- Iereation- Data: Under enna EP engin inretinjacton) Figure: B1CBO37D The diameter values for the crankshaft main bearings are referenced on the machined surface (1) of the cylinder block (at “g") (Direction of reading from the flywheel towards the timing). [Components|[Bearing n’] ik Is iP la I ik lz ik lr N.B. : Bearing n°1 flywheel end (Cylinder no 1). 4.2. Crankshaft main bearing cap casing 208- BIBBOI8HPO- Iereation- Data: Under enna EP engin inretinjacton) Figure: 81080860 ‘The engine serial numbers are referenced on the machined surface (2) of the crankshaft bearing cap casing (at, "«’, "). “h’ Area of marking (Machined surface) "j Manufacturer identification + Legislation type . "K" Identification marking . "’ Serial number. 1.3. Diameters of the crankshaft main bearings A co) Ce Se Figure BICBOseD 208- BIBBOI8HPO- Iereation- Data: Under enna EP engin inretinjacton) (8) Cylinder block (4) Bearing cap housing, [Components [Measurement alues ‘A [Measurement zone for the diameter of the cylinder block|0 to 4 mm 8" [Angle between each measurement |eo" 'C", C1", °C2"|Nominal diameter of the crankshaft [48,655 (0 ; + 0,079) mm] [Calculation of the diameter of the crankshaft bearing [OC + @C1 + 9C2)/3 2. Crankshaft [Crankshaft lateral play|0,07 mm minimum)0,32 mm maximurn] [axial play 0076 mm maximum ‘The cast-iron crankshaft is non-repairable. 2.1, References on crankshaft Figure = B1CB03AD ‘The diameter values for the main joumals and erank pins are referenced on the crankshaft (at "m’,*n") (Flywheel side). "im" Record ofthe value of the main journals (Machined surface) - Alphabetical characters. “n” Record of the value of the crank pins (Machined surface) - Alphabetical characters. N.B. : Direction of reading from the flywheel towards the timing. [Components *n"]Main journal bearing r" Ik P I N =sfepto | P 208- BIBBOI8HPO- Iereation- Data: Under enna EP engin inretinjacton) N.B. : Bearing n°t flywheel end (Cylinder no 1). [Components *m"[Crank pin bearing n’| N le P is N 2 IM hn N.B. : Bearing n*1 flywheel end (Cylinder no 1) 2.2. Crankshaft measurements Figure = B1CB0360 lengine [EPs EPS ['D" Nominal diameter of the main journal] 45 (0; - 0,016) mm_ [2 45 (05 -0,016) mm E* Nor [245 (0,009 ; - 0,025) mm| wal diameter of the crank pin [@ 40 (- 0,009; - 0,025) mm 208- BIBBOI8HPO- Iereation- Data: Under enna EP engin inretinjacton) Figure: B1BBOWVD lengine [EPS EPe 'F* Crank pin / main journal overlap]37,5 # 0,05 mm)42,9 + 0,05 mm| 2.3. Measurement of the diameter of the main journals Figure BIBBOWYD (Components|Measurement [values] 208- BIBBOI8HPO- Kercation- Data: Under enna EP engin inretinjacton) or ie Ingine| engi Calculation of the diameter of the main journal "D" © B= BI1+0)2+0N3 13 = 0K OL Diameter of the main journal "D" : (2D = QJ + OK + OL) /3. 3. Crankshaft bearing shells Figure = B1CB03CD CAUTION : The crankshaft bearing upper and lower half-shells are different. Colour-coded marking zone on the upper, grooved, half-shells (6). "q’ Colour-coded marking zone on the lower, smooth, half-shells (6). shells (crankshaft bearing cap casing side). {Classes of crankshaft bearing shells - EP3 - EP6 engine| (Colour identification [Nominal dimension [Blue [1,821 - 1,825 mm [Black [1,825 - 1,829 mm IGreen [1,829 - 1,833 mm ellow [1,833 - 1,837 mm [orange [1.837 - 1,841 mm N.B. : There are 5 classes of grooved upper crankshaft bearing half-shells and 5 classes of smooth lower half m4 208- BIBBOIBHPO- Iercation- Data: Under enna EP engin inretinjacton) [Classes of crankshaft bearing shells - EP3C - EPEC engine (Ealavesdteniiinntioart bearing| EHGTENBREC engine| [Brack B22 [Green 1,826 - 1,830 mm fellow [1.830 - 1,834 mm loran [1.894 — 1,838 mm [Brown [1.838 - 1,842 mm CAUTION : Half-shells on the same bearing may have colour references that differ. N.B. : Only the half-shells for engines EP3C and EP6C are available from replacement parts, replacing the old ones or engines EP3 and EP6 (Without a blue class). 4. Crankshaft lateral shims Figure = B1CB0300 ‘The lateral play of the crankshaft is assured by 2 identical shims (7) on the eylinder block. The shims are mounted on bearing n°2. EP3-EP6 JEPsc- EPEC [Thickness ofa lateral play shim|2,40 (0 ; + 0,05) mml2,35 (0; + 0,05) mm| NB. : Only the lateral play shims for engines EP3C and EPGC are available from replacement parts, replacing the old ones or engines EPS and EP6. 5. Conrods 208- BIBBOI8HPO- Iereation- Data: Under enna EP engin inretinjacton) Figure: 188050 Sectile conrods in forged steel. fengine [EPs Ere 18 (* 0,02; + 0,007) Imm he (+ 0,02; + 0,007) Imm. [43 (+ 0,016 ; 0) mm [48 (+ 0,016; 0) mm [144,69 = 0,025 mm [139,29 = 0,025 mm [Maximum permissible weight difference between conrods of the same [3 grammes [2 grammes: lengine [Direction of fitting identification (3rd boss towards the timing) ta a 208- BIBBOI8HPO- Iereation- Data: Under enna EP engin inretinjacton) Figure: B1880x80 ‘The conrod litte end has a bronze ring that is non-repairable. The whole is machined to the shape of a viper's head ("u") (After assembly). ‘The bronze ring is grooved (at ‘t"). Figure 618808 ‘A marking identifies the assembly of casing and body of the conrod for refiting (at "v'). 6. Big end half-shells ria 208- BIBBOI8HPO- Iereation- Data: Under enna EP engin inretinjacton) Figure: BICMOEGD [EPS - EPS engine| IEP3C - EPGC engine| [Thickness| f.492 - 1,498 mm [487 - 1,493 mm ‘The lower (8) and upper (9) big end half-shells are identical, smooth, without positioning lugs and have only one thickness clase N.B. : Only the conrod half-shells for engines EP3C and EPEC are available from replacement parts, replacing the old half shells on engines EP3 and EPS. 7. Piston cd 208- BIBBOIBHPO- Kercation- Data: Under enna EP engin inretinjcton) EP3- EPS - EPGC engin Figure: B1BB0xGD Marking in *w" (Arrow pointing to timing end). R1 R2 R3 R4 Figure BIBBOXID EP3 - EP6 - EP6C engine (Components [Height Piston diameter _[Siotting RI” (Nominal diamoter|'Q1" = 10 mm_[76,958 + 0,009 mm|- 0,490 + 0,03 mm: RO" [76,880 * 0,007 mmf 0,480 + 0,03 mm. waa 208- BIBBOIBHPO- Kercation- Data: Under enna EP engin inretinjcton) EPS - EPEC BREGengine fos = 38,1 mml76,463 + 0,015 mmf 0,180 + 0,02 mm ‘Q4" = 43,9 mm|76,278 + 0,045 mm 0,030 £ 0,015 mm) EP3C engine (Components Height Piston diameter [Siotting 1 (Nominal diameten['Q1" = 10 mm_[76,948 + 0,009 mmf- 0,490 + 0,03 mm RO fra2"= 25 mm_|76,870 + 0,007 mmf 0,480 + 0,03 mm Pra" fas® = 38.1 mm|76,473 + 0,015 mmf 0,180 + 0,02 mm Ra faa" = 43.9 mm|76.288 + 0,015 mmf, 0,030 + 0,075 mm N.B. : Only the pistons for engine EP3C are available from replacement parts, replacing the old pistons on engine EP3, 8. Piston rings 10 . Figure: B1BBOXUD (10) Rectangular fire stop ring, (11) Hooked sealing ring. (12) Scraper ring "u-flex". "x" Piston ring markings. ‘TOP marking oriented upwards. 194 208- BIBBOI8HPO- Iereation- Data: Under enna EP engin inretinjacton) Figure: B1BB0XPD PPiston rings FFire stop ring [Sealing ring [Scraper ring [Thickness 1,2 (- 0,005 ; - 0,03) mm|1,5 (0,005 ; -0,03) mmf2 (-0,01 ;-0,05) mm learance at the gapl0,.2(+0,20;0)mm —_[0.3(+0,26;0) mm |Without (Blue colour marking) ['S" Diameter iColour [77 mm/ Mauve [77 mm Yellow [77 mm Without 9. The piston shaft The piston shafts are free-fitted in the little ends and the pistons, then laterally immobilised by means of two stop rings. [Extemal diameter[18 (0 ; - 0,005) mm] length [43 (0; -0,3) mm wie 208. BIBBO160PO - Tighteing torques: Engine assembly mountings - gearbox TIGHTENING TORQUES : ENGINE ASSEMBLY MOUNTINGS - GEARBOX 1. RH engine support Figure: B7BB0"MD [Reference[Designation [Tightening torques| a bolts (Right hand flexible engine mounting / Right-hand intermediate mounting )|6 daNm (2) bolts (Right-hand intermediate engine mounting / Cylinder head) [4.5 daNm (a) loolts (Right hand flexible engine mounting / Front right chassis leg } [4.5 daNm 2. LH gearbox support (MA gearbox) 16 208 -BIBBO160PO -Tightoring oxques : Engine assembly mountings - osarbox 2 s 8 Figure: 1897000 [Reference[Designation [Tightening torques (1) [bolts (Upper left flexible mounting / Intermediate gearbox mounting )|6 daNm_ e loots (Upper eft Rexible mounting /L.H. front chassis eg) [535 dan ‘ey bolts (Intermediate gearbox mounting / Gearbox easing) PB dam 3. LH gearbox support (BE gearbox) 208 -BIBBO160PO -Tightoring oxques : Engine assembly mountings - osarbox Figure: 818810£D [Reference[Designation [Tightening torques] io bolts (Upper left flexible mounting / Intermediate gearbox mounting )|6 daNm (2) [bolts (Upper left flexible mounting / Body) [5.5 daNm (3) [bolts (Intermediate gearbox mounting / Gearbox casing) [b dam 4. LH gearbox support (AL4 gearbox) Figure: B16B7GFD [Reference[Designation [Tightening torques] a [bolts (Upper left flexible mounting / Intermediate gearbox mounting )|6 daNm. (2) [bolts (Upper left flexible mounting / Body) [5.5 daNm (a) [bolts (intermediate gearbox mounting / Gearbox casing) [e-canm 5, Lower torque reaction rod (MA gearbox) 208 -BIBBO160PO -Tightoring oxques : Engine assembly mountings - osarbox Figure: 81881060 |Reference|Designation [Tightening torques| (1) [bolts (Reaction link yoke / gearbox) [8.5 daNm_ (2) pots (Reaction rod Front subjrame) [5 daNm [2)__botis (Reaction tink yoke / Reaction rod)[6 daNtm 6. Lower torque reaction rod(BE gearbox) 208 -BIBBO160PO -Tightoring oxques : Engine assembly mountings - osarbox Figure: 818810HD [Reference[Designation [Tightening torques a tts (Reaction ink yoke /gearbox) [6 daNm 2) lbolts (Reaction rod / Front subframe) [4 daNm (3) bolts (Reaction rod / Reaction link yoke)|4 daNm la bolts (Reaction ink yoke / gearbox) [6 daNm oy bolts (Reaction ink yoke / gearbox) [6 daNm 7. Lower torque reaction rod (AL4 gearbox) Figure: 81887010 [Reference[Designation io bolts (Reaction ink yoke /gearbox) [6 dam (2 loots (Reaction rod / Front subframe) [6 daNim o bolts (Reaction rod / Reaction link yoke)|6 daNm 208- B1BDO1ISPO- Checking: Presstre, engino end of cemprassion CHECKING : PRESSURE, ENGINE END OF COMPRESSION ESSENTIAL : Observe the safely and cleanliness recommendations © ‘CAUTION : Checking is carried out with the engine cold. Disconnect the ancillaries battery. Remove : ‘© The fuse of the fuel pump gauge The sparking plugs CAUTION : Perform the operations that are required following a reconnection of the ancillaries battery Reconnect the ancillaries battery. Ensure that the speed of engine rotation, driven by the starter, is correct (Minimal value ) : 250 rpm. Checks ‘+ Place the end of compression measurement unit on the base of the spark plug of cylinder No.1 ‘+ Keep pressure on the end of compression measurement unit ‘© Operate the starter '* Check that an end of compression measurement has been taken + Note the value ‘© Reset the measurement unit Proceed in the same way for the other eylinders, ‘CAUTION : Look for the origin of the fault if there is an appreciable difference between the measured values. Disconnect the ancillaries battery CAUTION : Adhere to the lightening torques. Refit: ‘© The sparking plugs ‘© The fuse of the fuel pump gauge CAUTION : Perform the operations that are required following a reconnection of the ancillaries battery. Reconnect the ancillaries battery. Read the diagnostic memories ; Using the diagnostic equipment, " 208 B18G018/E0- Removing - Rafting :Enginagoarbox assembly REMOVING - REFITTING : ENGINE/GEARBOX ASSEMBLY ESSENTIAL : Observe the safely and cleanliness recommendations © ESSENTIAL : Wait at least one hour before carrying out any work on the exhaust line. 1. Tooling (ool lReference[Description (0141-11) |Pipe with adaptor for SHRADER valve] (0141-11) Figure EBABOSIT (0004) iting bench [0004] Figure = ESABOKT [0005-C]_ [set of retaining supports +H0 208 B18G018/E0- Removing - Rafting :Enginagoarbox assembly [1520] 4 4 Figure ESAGOeWT (0005-G]_ [sot of retaining supports [0005] (c] []. Figure: ESABOBZT 1520] [2 plugs for click-fit unions 2. Removing N.B. : Do not drain the air conditioning circuit. Place the vehicle on a 2-post lift. 2110 208 B18G018/E0- Removing - Rafting :Enginagoarbox assembly Figure: B1BG3C80 Disconnect the ancillaries battery. Unolip the vacuum circuit pipe (at "a"). Remove : +The air resonator (2) ‘© The air entry union (3) ‘+The screw (4) ofthe air inlet manifold ‘+ The air fiter cover bolts (1), (5) ‘+The air fiter cover (6) The service battery Move the engine management ECU aside. Release the harnesses from the ancillaries (service) battery tray. Remove the service battery tray. 10 208 B18G018/E0- Removing - Rafting :Enginagoarbox assembly Figure: B18G3C30 Remove : ‘© The bolts (7) ‘© The intermediate mounting (8) ‘= The air fiter housing (9) CAUTION : Fit plugs at the inlet manifold air inlet. Unplug : * The connectors of the electrical hamess (10) (at "c", "d") ‘* The reverse gear connector (at "e") + The engine management ECU (11) connectors (at"b") Remove = ‘+ The engine management ECU (11) * The accessories drive belt © 410 208 B18G018/E0- Removing - Rafting :Enginagoarbox assembly Figure: B1BG3CAD Remove the bolt (16). Move the earth cable (14) aside. Unclip the gearbox control cables (13) (at) Remove the bolt (15) from the cables support (12). Figure BiBGECsD ESSENTIAL : Drop the fuel pressure by coupling the end of tool [0141-T1] on the SCHRADER valve and collect the petrol in a container (at “g") 10 208 B18G018/E0- Removing - Rafting :Enginagoarbox assembly CAUTION : Before uncoupling, clean all the unions on the low pressure circuit . Uncouple the fuel pipes (17), (18) and release them from the bodywork. CAUTION : Blank the fuel pipes (17), (18) ; Using tool [1520]. Figur BrBG308D Drain : «The gearbox O © The cooling system: Remove the exhaust clamp (27). Move aside and clip the exhaust line (26). Remove : ‘© The front splash shields ‘The subframe The drive shafts © The bolts (24) The reaction link (25) ‘The cable support (12) bolt (22) Release the cable support (12). Remove the bolts (21). Move aside the clutch slave cylinder (23) without opening the hydraulic circuit Disconnect the air conditioning compressor (19) connectors (at "h’). Remove the bolts (20). Move aside and secure the air conditioning compressor (19). a0 208 B18G018/E0- Removing - Rafting :Enginagoarbox assembly a I ey z = i= 4 , EGA

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