Removing - refitting: power unit (DV4TD) Citroen C2 I

Recommended tools

[1] hub immobilising tool 6310-T

[2] pivot ball-joint uncoupling lever 9509-T

[3] pliers for removing and refitting hose clips 9029-T

[4] pliers to remove "clic" clips (-).0172.Z

[5] lifting bench 5702-T.A

[6] engine supports 5704-T

[7] final drive right-hand output oil seal fitting drift 7114-T.X (addition to tool box 7116-T)

[8] final drive left-hand output oil seal fitting drift 7114-T.W (addition to tool box 7116-T)

Removing

Disconnect the battery

Raise the vehicle and support on axle stands, wheels free

Remove the front wheels

Remove the drive shafts (see the relevant operation)

Drain the cooling system (see the relevant operation)

Drain the gearbox (see the relevant operation)

Remove the front bumper (see the relevant operation)

Remove the screws fixing the air duct on the integrated air manifold

Remove the air conduit (3)

Remove the battery

Disconnect the 3 connectors of the injection ECU (take care when handling the special connectors)

Remove

• The injection ECU (2)
• The separator between the battery and the electric power steering ECU

Disconnect the 3 connectors of the electric power steering ECU

Remove

• The electric power steering ECU (1)
• The 2 battery mounting fixing screws
• The battery support

Remove: the 2 fixing screws from each side of the radiator/cooling fan assembly mounting

Uncouple the 2 hoses from the radiator

Disconnect the expansion chamber return tube from the radiator

Remove the fan assembly and the radiator

Fuse box

Unplug

• The connector (4)
• The black 2 (5) -way connector
• The nut (6) fixing the 3 earth wires

Remove the pre- and post-heating control unit (under the wing and the front RH headlamp)

Remove the bolts (7)

Move aside the clutch slave cylinder (8) without opening the hydraulic circuit

Uncouple the click-fit unions of the fuel supply and return pipes (9)

Under the vehicle

Uncouple

• The clip fixing the exhaust line close to the rubber pipe
• The torque reaction rod mounting (engine side)

Uncouple

• The ball joint (12)
• The ball joint (13)

Uncouple

• The cable end stop (10) (pull on the locking pin)
• The cable end stop (11) (pull on the locking pin)
• The coolant housing inlet hose

Put lifting table [5] together with its supports [6] in position under the engine

Remove the 2 bolts (14)

Remove

• The 3 bolts (16)
• The 2 bolts (17)
• The right-hand engine mounting (15)

Remove the power unit assembly from under the vehicle

Refitting

Position the lifting bench [5] with the engine-gearbox assembly at the marks made at removal

Proceed in the reverse order to removal

Replace the final drive output lip seals with the aid of mandrels [7] and [8], having greased between the lips

Fit the engine/gearbox assembly

Refit

• The right-hand engine mounting (15)
• The screws (16) and (17)
• The bolts (14)
• The reaction link
• The exhaust

Connect and clip the hoses, harnesses and cables connected to the power unit

Refit

• The drive shafts (see the relevant operation)
• The battery

Refit the air duct

Fill and top up the level of the following of the following elements

• Gearbox
• Cooling system

Bleed the cooling system (see the relevant operation)

Return the vehicle to its wheels