Engine and gearbox assembly

Essential special tools
Mot. 1202-01	Spring clamp pliers (large model)
Mot. 1202-02	Spring clamp pliers (small model)
Mot. 1448	Remote spring clamp pliers

Essential equipment

safety straps

charging station

load positioner

Tightening torques
Lower ball joint nut	6.2 daN.m
Driveshaft nut	28 daN.m
Steering ball joint nut	3.7 daN.m
Upper pendulum suspension link bolt	10.5 daN.m
Upper front end panel bolt	2.1 daN.m
Lower front end panel bolt	4.4 daN.m
Pendulum suspension cover bolt on engine	6.2 daN.m
Torque reaction rod bolt (on subframe)	10.5 daN.m
Torque reaction rod bolt (on F engines)	18 daN.m
Torque reaction rod bolt (on K engines)	10.5 daN.m
Wheel bolt	11 daN.m
Front radiator crossmember bolt	10.5 daN.m
Rear crossmember bolt	2.1 daN.m

REMOVAL

• Position the vehicle on a two-post lift.

Note: During this operation, secure the vehicle to the lift using vehicle safety straps to prevent imbalance (see Lifting equipment chapter).

• Disconnect the battery.
• Remove:

• the engine covers,
• the front wheels,
• the engine undershield,
• the right and left mudguards.

• Drain:

• the refrigerant circuit using a charging station,
• the cooling circuit at the lower radiator hose using tools (Mot. 1202-01), (Mot. 1202-02) and (Mot. 1448),
• the gearbox if necessary,
• the engine if necessary.

• Remove:

• the side reinforcements of the radiator crossmember (1),
• the bumper mountings,
• the bumper cover

• Disconnect the two connectors (2).
• Unclip the bonnet release cable (3).
• Remove:

• the clip (4),
• the mounting (5).

• Disconnect the windscreen washer pipes.

• Remove:

• the front end panel mounting bolts (6),
• the front end panel.

K4J

• Disconnect the fuel supply fitting (7).

F4R or K4M

• Disconnect the fuel supply hose (8) from the injection rail.

F9Q or K9K

WARNING

• Strictly observe the cleanliness precautions (Diesel Injection chapter, Diesel Injection Safety, page 13B-9).
• Be aware of the amount of diesel and the residual pressure in the lines.

• Remove:

• the fuel supply hose (9),
• the fuel return hose (10).

• Disconnect the electrical connector (11).
• Fit plugs to the openings.
• Disconnect the connector from the cooling fan assembly.
• Disconnect the upper radiator hose using tool (Mot. 1202-01) or (Mot. 1202-02) or (Mot. 448).

• Disconnect the two hoses from the radiator expansion tank.
• Remove:

• the two A/C lines from the condenser,
• the cooling assembly,
• the A/C line between the A/C compressor and the receiver-drier.

Note: Be sure to fit plugs to the pipes and the expansion valve to prevent moisture from entering the circuit.

K4J

• Remove the bracket (12) from the air resonator.
• Remove:

• the air resonator,
• the battery.

F4R or F9Q or K4M or K9K

• Remove the air filter outlet duct.

• Remove the battery tray mounting bolts (13).
• Disconnect the control unit connectors.
• Remove:

• the battery tray,
• the control unit bracket.

• Disconnect:

• the relay box harness connectors,
• the earth strap from the body.

• Remove the brake booster hose (14).

• Disconnect the heater matrix hoses from the coolant housing using tools (Mot. 1202-01), (Mot. 1202-02) and (Mot. 1448).
• Disconnect the oxygen sensors.

• Remove the gearbox controls (15).

CAUTION Do not touch the gearbox selector spool.

• Release the two cables from the gearbox levers:

• pinch the gearbox control at (A),
• pull out the pin at (B),
• lift the gearbox control at (C).

DP0

• Remove:

• the ball joint (16) of the multifunction switch cable,
• the wiring (17) of the multifunction switch cable by releasing the cable sheath stop.

K4J or K4M or K9K

• Remove the hydraulic clutch control (18).

F4R or F9Q

• Press the clip.
• Disconnect the supply line.
• Remove the hydraulic clutch control from the bulkhead.

Note: Plug the line to prevent fluid from escaping.

• Remove:

• the driveshafts (Transmission chapter),
• the exhaust downpipe mountings,
• the lower torque reaction rod,
• the upper torque reaction rod (F9Q and F4R engines only),
• the lower radiator crossmember (19).

• Fit the workshop crane fitted with a load positioner or a chain.

IMPORTANT The chain must be at least 90 cm long.

K4J or K4M or K9K

• Remove:

• the engine pendulum mount,
• the gearbox pendulum mount,
• the "engine - gearbox" assembly.

F4R or F9Q

• Remove:

• the engine pendulum mount,
• the gearbox pendulum mount,
• the "engine - gearbox" assembly.

INSTALLATION

• Position the "engine - gearbox" assembly in the vehicle.
• Refit:

• the engine pendulum mount (Engine Mounting chapter, Setting Values - pendulum mount, page 19D-1),
• the gearbox pendulum mount (Engine Mounting chapter, Setting Values - pendulum mount, page 19D-1),
• the lower torque reaction rod (Engine Mounting chapter).

F4R or F9Q

• the upper torque reaction rod (Engine Mounting chapter).
• Refit in the reverse order of removal.
• Tighten to the following torques:

• the lower ball joint nut (6.2 daN.m),
• the driveshaft nut (28 daN.m),
• the steering ball joint nut (3.7 daN.m),
• the upper pendulum mount bracket bolt (10.5 daN.m),
• the upper front end mounting bolt (2.1 daN.m),
• the lower front end mounting bolt (4.4 daN.m),
• the pendulum mount cover bolt to engine (6.2 daN.m),
• the torque reaction rod bolt (to subframe) (10.5 daN.m),
• the torque reaction rod bolt (on F engines) (18 daN.m),
• the torque reaction rod bolt (on K engines) (10.5 daN.m),
• the wheel bolt (11 daN.m),
• the front radiator crossmember bolt (10.5 daN.m),
• the rear crossmember bolt (2.1 daN.m).

• Add brake fluid to the brake fluid reservoir.

Carry out:

• the clutch bleeding (Mechanical Controls chapter),
• topping up the gearbox oil if necessary,
• topping up the engine oil if necessary,
• filling and bleeding the coolant (Cooling chapter),
• recharging the refrigerant circuit using a recharging station.

IMPORTANT

• Press the brake pedal several times to bring the pistons, pads and brake discs into contact.
• Correctly secure the brake hose and the anti-lock braking system wheel sensor wiring.

WARNING

Connect the battery; carry out the necessary re-learns (see Electrical Equipment chapter).

Note: Be sure to initialise the xenon lighting system (if the vehicle is so equipped; see Xenon lamps chapter).