Engine - Gearbox

D7F engine

REMOVAL

Place the vehicle on a two-post lift.

Disconnect:

• the battery,
• the electrical connectors on the engine interconnection box and its surroundings.

Drain:

• the cooling circuit (lower radiator hose),
• the gearbox oil,
• the engine oil if necessary.

Remove:

• the battery,
• the bonnet,
• the wheels,
• the air intake duct,
• the expansion tank, secure it to the engine.

Left side of the vehicle

Remove:

• the brake caliper mounting bolt, then secure it to the shock absorber spring,
• the three transmission boot mounting screws,
• the steering ball joint using tool T. Av. 476,
• the shock absorber base bolts.

Tilt the hub to disconnect the transmission from the gearbox.

Right side of the vehicle

Remove:

• the transmission pins using the pins B. Vi. 31-01,
• the brake caliper mounting bolt, then secure it to the shock absorber spring,
• the steering ball joint using tool T. Av. 476,
• the shock absorber base bolts.

Tilt the hub to disconnect the transmission from the gearbox.

Remove the earth strap mounting screw (gearbox side).

Disconnect the gear selector at the gearbox output lever after releasing the boot.

Loosen bolt (A) without removing it, and remove bolt (B) from the torque reaction rod.

Disconnect:

• the accelerator cable,
• the canister hose,
• the brake servo vacuum hose,
• the hoses between radiator and engine block, engine block side,
• the heater hoses on the bulkhead side (with plastic fittings),

(with metal fittings),

• the oxygen sensor and cooling fan motor connectors,
• the fuel pipes.

Remove:

• the ECU support bracket,
• the power steering pipe mountings on the engine,
• the power steering pump belt (see chapter 07),
• the power steering pulley,
• the power steering bolts.

Release the power steering.

Fit the load positioner to the engine lifting eyes.

Remove:

• the gearbox side mounting,

• the mounting bolts (2) of the engine mounting insulator (1).

Mark the position of the engine mounting insulator (1) relative to the body.

Remove the powertrain after releasing the power steering from the engine compartment and protecting the radiator.

REFITTING (Specific points)

Refit in the reverse order of removal.

Tighten the pendulum mount fixing bolts to torque.

NOTE: observe the tightening sequence for the pendulum mount fixings to the body in the order given below:

• 1 ⇒ bolt mark A to torque 2.1 daNm.
• 2 ⇒ bolt mark B to torque 2.1 daNm.
• 3 ⇒ bolt mark C to torque 2.1 daNm.

Apply RHODORSEAL 5661 to the transmission dowel hole.

Press the brake pedal several times to bring the pistons into contact with the brake pads.

Refit the power steering pump belt (see chapter 07).

Carry out:

• a gearbox oil top-up,
• an engine oil top-up (if necessary),
• a coolant top-up and bleeding of the cooling system (see chapter 19).