23 Lift the engine/transmission out of the car,
ensuring that nothing is trapped or damaged.
Enlist the help of an assistant during this
procedure, as it will be necessary to tilt the
assembly slightly to clear the body panels. On
models equipped with anti-lock brakes, great
care must be taken to ensure that the anti-
lock braking system unit is not damaged
during the removal procedure.
24 Once the engine is high enough, lift it out
over the front of the body, and lower the unit
to the ground.
Separation
25 With the engine/transmission assembly
removed, support the assembly on suitable
blocks of wood, on a workbench (or alter-
natively, on a clean area of the workshop
floor).
26 Undo the retaining bolts, and remove the
flywheel lower cover plate (where fitted) from
the transmission.
27 On models with a “pull-type” clutch
release mechanism (see Chapter 6 for further
information), tap out the retaining pin or
unscrew the retaining bolt (as applicable), and
remove the clutch release lever from the top
of the release fork shaft. This is necessary to
allow the fork shaft to rotate freely, so that it
disengages from the release bearing as the
transmission is pulled away from the engine.
Make an alignment mark across the centre of
the clutch release fork shaft, using a scriber,
paint or similar, and mark its relative position
on the transmission housing (see Chapter 7A
for further information).
28 Slacken and remove the retaining bolts,
and remove the starter motor from the
transmission.
29 Ensure that both engine and transmission
are adequately supported, then slacken and
remove the remaining bolts securing the
transmission housing to the engine. Note the
correct fitted positions of each bolt (and the
relevant brackets) as they are removed, to use
as a reference on refitting.
30 Carefully withdraw the transmission from
the engine, ensuring that the weight of the
transmission is not allowed to hang on the
input shaft while it is engaged with the clutch
friction disc.
31 If they are loose, remove the locating
dowels from the engine or transmission, and
keep them in a safe place.
32 On models with a “pull-type” clutch, make
a second alignment mark on the transmission
housing, marking the relative position of the
release fork mark after removal. This should
indicate the angle at which the release fork is
positioned. The mark can then be used to
position the release fork prior to installation, to
ensure that the fork correctly engages with
the clutch release bearing as the transmission
is installed.
Refitting
33 If the engine and transmission have been
separated, perform the operations described
below in paragraphs 34 to 42. If not, proceed
as described from paragraph 43 onwards.
34 Apply a smear of high-melting-point
grease (Peugeot recommend the use of
Molykote BR2 plus - available from your
Peugeot dealer) to the splines of the
transmission input shaft. Do not apply too
much, otherwise there is a possibility of the
grease contaminating the clutch friction plate.
35 Ensure that the locating dowels are
correctly positioned in the engine or
transmission.
36 On models with a “pull-type” clutch,
before refitting, position the clutch release
bearing so that its arrow mark is pointing
upwards (bearing fork slots facing towards the
front of the engine), and align the release fork
shaft mark with the second mark made on the
transmission housing (release fork positioned
at approximately 60° to clutch housing face).
This will ensure that the release fork and
bearing will engage correctly as the
transmission is refitted to the engine.
37 Carefully offer the transmission to the
engine, until the locating dowels are engaged.
Ensure that the weight of the transmission is
not allowed to hang on the input shaft as it is
engaged with the clutch friction disc.
38 On models with a “pull-type” clutch, with
the transmission fully engaged with the
engine, check that the release fork and
bearing are correctly engaged. If the release
fork and bearing are correctly engaged, the
mark on the release fork should be aligned
with the original mark made on the
transmission housing (see Chapter 7A for
further information).
39 Refit the transmission housing-to-engine
bolts, ensuring that all the necessary brackets
are correctly positioned, and tighten them to
the specified torque setting.
40 Refit the starter motor, and securely
tighten its retaining bolts.
41 On models with a “pull-type” clutch
release mechanism, refit the clutch release
lever to the top of the release fork shaft,
securing it in position with its retaining pin or
bolt (as applicable).
42 Where necessary, refit the lower flywheel
cover plate to the transmission, and securely
tighten its retaining bolts.
43 Reconnect the hoist and lifting tackle to
the engine lifting brackets. With the aid of an
assistant, lift the assembly over the engine
compartment.
44 The assembly should be tilted as
necessary to clear the surrounding
components, as during removal; lower the
assembly into position in the engine
compartment, manipulating the hoist and
lifting tackle as necessary.
45 With the engine/transmission in position,
refit the right-hand engine/transmission
mounting bracket, tightening its retaining nuts
and bolts (as applicable) by hand only at this
stage.
46 Working on the left-hand mounting, refit
the mounting bracket (where removed) to the
body and tighten its retaining bolts to the
specified torque. Refit the mounting rubber
and refit the mounting retaining nuts and
washers and the centre nut and washer,
tightening them lightly only.
47 From underneath the vehicle, refit the rear
mounting link and install both its bolts.
48 Rock the engine to settle it on its
mountings then go around and tighten all the
mounting nuts and bolts to their specified
torque settings. Where necessary, once the
right-hand mounting bracket nuts have been
tightened, refit the rubber damper and curved
retaining plate, tightening its retaining bolts to
the specified torque. The hoist can then be
detached from the engine and removed.
49 The remainder of the refitting procedure is
a direct reversal of the removal sequence,
noting the following points:
a) Ensure that the wiring loom is correctly
routed and retained by all the relevant
retaining clips; all connectors should be
correctly and securely reconnected.
b) Prior to refitting the driveshafts to the
transmission, renew the driveshaft oil
seals as described in Chapter 7A.
c) Ensure that all coolant hoses are correctly
reconnected, and securely retained by
their retaining clips.
d) Adjust the clutch cable as described in
Chapter 6.
e) Adjust the choke cable and/or accelerator
cable (as applicable) as described in the
relevant Part of Chapter 4.
f) Refill the engine and transmission with
correct quantity and type of lubricant, as
described in Chapter 7A.
g) Refill the cooling system as described in
Chapter 1.
5
Engine and automatic
transmission - removal,
separation and refitting
4
Removal
Note: The engine can be removed from the
car only as a complete unit with the
transmission; the two are then separated for
overhaul.
1 Carry out the relevant operations described
in paragraphs 1 to 24 of Section 4, noting that
the transmission oil draining procedure is
given in Chapter 1. Before lifting the engine
from the engine compartment, carry out the
following operations, using the information
given in Chapter 7B:
a) Remove the transmission dipstick tube.
b) Disconnect the wiring from the starter
inhibitor/reversing light switch and the
speedometer drive housing. Release the
earth strap(s) from the top of the
transmission housing.
c) Disconnect the selector cable.
d) Release the power steering pipe from the
transmission.
e) Disconnect the speedometer cable.
2C•6 Engine removal and overhaul