10A-96
ENGINE AND CYLINDER BLOCK ASSEMBLY
Engine - gearbox assembly: Removal - Refitting
K4M
10A
REMOVAL
I - REMOVAL PREPARATION OPERATION
aPosition the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).
aRemove the air filter unit (see 12A, Fuel mixture,
Air filter unit: Removal - Refitting, page 12A-13) .
aRemove the battery (see Battery: Removal - Refit-
ting) (80A, Battery).
aRemove:
-the petrol injection computer (see 17B, Petrol in-
jection, Petrol injection computer: Removal -
Refitting, page 17B-20) ,
-the battery tray (see Battery tray: Removal - Re-
fitting) (80A, Battery),
-the front wheels (see Wheel: Removal - Refitting)
(35A, Wheels and tyres),
-the engine undertray,
-the front wheel arch liners (see Front wheel arch
liner: Removal - Refitting) (55A, Exterior protec-
tion),
-the front bumper (see Front bumper: Removal -
Refitting) (55A, Exterior protection).
aDrain:
-the gearbox (see Manual gearbox oils: Draining -
Filling) (21A, Manual gearbox),-the cooling system (see 19A, Cooling, Cooling
system: Draining - Refilling, page 19A-9) ,
-the engine, if necessary (see 10A, Engine and
cylinder block assembly, Engine oil: Draining -
Refilling, page 10A-22) ,
-the refrigerant circuit using a refrigerant charging
station (see Refrigerant circuit: Draining - Fill-
ing) (62A, Air conditioning).
aAttach the « engine cooling radiator - condenser »
assembly to the front upper cross member.
aRemove:
-the engine tie-bar (see 19D, Engine mounting,
Lower engine tie-bar: Removal - Refitting, page
19D-18) ,
-the front axle subframe (see Front axle subframe:
Removal - Refitting) (31A, Front axle compo-
nents),
-the radiator mounting cross member (see Radiator
mounting cross member: Removal - Refitting)
(41A, Front lower structure),
-the front left-hand wheel driveshaft (see Front left-
hand driveshaft: Removal - Refitting) (29A,
Driveshafts),
-the front right-hand wheel driveshaft (see Front
right-hand driveshaft: Removal - Refitting)
(29A, Driveshafts),
-the differential output seal (see Differential output
seal: Removal - Refitting) (21A, Manual gear-
box).
aRemove the catalytic converter (see 19B, Exhaust,
Catalytic converter: Removal - Refitting, page
19B-12) . Special tooling required
Mot. 1448Remote operation pliers for
hose clips .
Equipment required
refrigerant charging station
Tightening torquesm
rubber pad mounting
bolts for the suspended
engine mounting on the
gearbox21 N.m
bolts of the suspended
mounting r ubber pad62 N.m
suspended engine
mounting shaft nut62 N.m
10A-97
ENGINE AND CYLINDER BLOCK ASSEMBLY
Engine - gearbox assembly: Removal - Refitting
K4M
10A
aRemove using the (Mot. 1448) :
-the clip (6) from the top hose on the water cham-
ber,
-the clip (7) from each heater matrix hose.
aDisconnect:
-the top hose on the water chamber,
-the heater matrix hoses.aUnclip:
-the gearbox controls (8) on the gear selectors,
-the gearbox controls on the cable sleeve stops at
(9) ,
-the hydraulic clutch control pipe on the gearbox at
(10) .
aDisconnect the hydraulic clutch control pipe from the
gearbox by pressing on the clip (11) .
aFit blanking plugs on the hydraulic clutch control
pipe openings and on the opening of the clutch
thrust bearing.
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10A-98
ENGINE AND CYLINDER BLOCK ASSEMBLY
Engine - gearbox assembly: Removal - Refitting
K4M
10A
aDisconnect:
-the fuel vapour absorber bleed solenoid valve pipe
(12) ,
-the fuel vapour absorber bleed solenoid valve con-
nector (13) .aUnclip the fuel supply pipe at (14) .
aDisconnect the fuel supply pipe (15) .
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WARNING
To prevent impur ities from entering the circuit,
place protective plugs on all fuel circuit compo-
nents exposed to the open air.
10A-99
ENGINE AND CYLINDER BLOCK ASSEMBLY
Engine - gearbox assembly: Removal - Refitting
K4M
10A
aDisconnect:
-the engine cooling fan assembly resistor connector
(16) ,
-the engine cooling fan assembly connector (17) .
aUnclip:
-the engine cooling fan assembly wiring at (18) ,
-the cooling radiator top and bottom hose from the
engine cooling fan assembly.aRemove:
-the engine compartment connection unit cover
bolts (19) ,
-the cover of the engine compartment connection
unit.
aDisconnect the connector (20) from the engine com-
partment connection unit.
aRemove the engine compartment connection unit
nuts (21) from the body.
aMove the engine compartment connection unit to
one side.
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10A-100
ENGINE AND CYLINDER BLOCK ASSEMBLY
Engine - gearbox assembly: Removal - Refitting
K4M
10A
aRemove the earth nuts (22) .
aDisconnect the fuses (23) .
aUnclip:
-the fuse-holders,
-the engine compartment connection unit relay
plates (24) .
aRemove the earth nut (25) .aRemove the coolant pump inlet pipe hose clip (26)
using the tool (Mot. 1448).
aDisconnect the hose from the coolant pump inlet
pipe.
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10A-101
ENGINE AND CYLINDER BLOCK ASSEMBLY
Engine - gearbox assembly: Removal - Refitting
K4M
10A
aRemove:
-the bolt (27) from the « compressor - intermediate
pipe » connecting pipe,
-the bolt (28) on the « compressor - condenser »
connecting pipe,
-the bolt (29) from the « compressor - intermediate
pipe » connecting pipe mounting.
aDisconnect:
-the pressure sensor connector (30) ,
-the « compressor - intermediate pipe » connecting
pipe,-the « compressor - condenser » connecting pipe.
aInsert the blanking plugs.
aDisconnect the brake servo vacuum pipe union (31)
.
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132335
WARNING
To prevent moisture from entering the system,
place plugs on the cold loop components which
are open to the air.
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10A-102
ENGINE AND CYLINDER BLOCK ASSEMBLY
Engine - gearbox assembly: Removal - Refitting
K4M
10A
aSupport the engine - gearbox assembly on theat
(32) .II - REMOVAL OPERATION
aRemove:
-the nut (33) from the suspended engine mounting
rubber pad shaft on the gearbox.
-the bolts (34) of the rubber pad of the suspended
engine mounting from the gearbox,
-the suspended engine mounting rubber pad from
the gearbox.
aRemove:
-the rubber pad mounting bolts (35) from the sus-
pended engine mounting on the gearbox,
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