Removing - refitting: engine/gearbox assembly (DV6UC) Citroen Jumpy II

Tooling

Removing

Place the vehicle on a 2-post lift

Disconnect the battery

Remove the engine style cover

Drain

• The cooling system
• The gearbox

Remove

• The front wheels
• The front splash shields
• The drive shafts
• The front bumper
• The headlamps

Uncouple the exhaust hose from the catalytic converter

Remove the exhaust line flexible mountings

Move aside the exhaust line

Remove

• The venting unit (1)
• The water evacuation pipes (3), (4), (10)
• The air inlet manifold (2)
• The bumper crossmember (5)
• The engine compartment lower crossmember (6) (according to equipment)
• The relay box (9)

Release

• The bonnet opening cable (8)
• The venting unit (1)
• The relay box (9)

Disconnect and move aside the cooling cassette (7) electrical harnesses

Remove

• The cooling cassette (7) fixing bolts
• The engine turbocharger air cooler
• The engine cooling radiator

Vehicle with air conditioning

Disconnect the connector (at "a")

Move aside the electrical harness

Remove

• The accessories drive belt
• The 3 bolts (11)

Without uncoupling the piping, move aside and secure the air conditioning compressor (12)

Separate the air conditioning condenser from the cooling cassette (7) (without opening the air conditioning fluid circuit)

Move aside and clamp the air conditioning condenser

Removing (continued)

Remove the cooling cassette (7)

Clamp the power steering pump supply pipe (18); using tool [4153-T / 1512]

Slacken the power steering high pressure pipe (14); using tool [4220-T.D / 1603-G]

Uncouple

• The power steering pump (19)
• The power steering high pressure pipe (14)
• The power steering pump supply pipe (18)

Plug the hydraulic unit unions; using cleanliness plugs

Remove the power steering fluid reservoir (13) (without opening the hydraulic circuit)

Unclip and move aside the power steering fluid reservoir (13) and piping (16) assembly

Remove

• The lower crossmember (17)
• The clutch slave cylinder (15) fixings

Move aside the clutch slave cylinder (15) (without opening the hydraulic circuit)

Remove, unclip or move aside: the pressure take-offs of the exhaust gas pressure sensor

Remove

• The engine fuse box (20) cover
• The securing clip (at "c")

Uncouple and move aside the fuel supply and return pipes (at "b"); plug by means of the tool [0194-T]

Disconnect the electrical harness (at "d")

Unclip the wiring harness from the body and move it aside

Remove the air inlet duct on the air filter (24)

Detach and move aside: the hoses (21)

Disconnect the pneumatic suspension ECU connectors (according to equipment)

Remove the pneumatic suspension ECU (according to equipment)

Unplug

• The pre-post heating relay (22)
• The connector (at "e")
• The engine management ECU (23) (en "f")

Disconnect and move aside

• The earth wire on the front left chassis member (at "g")
• The engine harness (25) attached to the body

Uncouple and unclip the vacuum pipe (27) from the vacuum pump (26) (at "h")

Unclip, move aside and secure: the vacuum pipe (27) (at "j")

Uncouple and move aside the gearbox controls (28); using tool [0216]

Disconnect the reversing lamps connector (on the gearbox)

Disconnect the earth wire (on the gearbox)

Remove the lower torque reaction rod from the engine subframe

Position the lifting table [0004] and the supports [0005-C] (under the engine/gearbox assembly)

Fix the intermediate support [0005-C] on the left-hand driveshaft bearing (at "k")

Vehicle without air conditioning

Fit tools [[0005-H1]] and [[0005-E]] onto the cylinder block

Vehicle with air conditioning

Fix the tool [0005-C] on the air conditioning compressor support (at "l")

Removing (continued)

Fit the tool [0005-C] on the blind hole on the gearbox

Fitthe tool [0005-G] in the blind hole on the cylinder block

Tighten all of the fixings of the supports [0004], [0005-G], [0005-C], [0005-H1], [0005-E]

Lift the engine-gearbox assembly slightly; using the lifting table [0004]

Mark the location of the lifting table [0004] on the ground

Remove

• The 3 support (30) bolts (29)
• The nut (34) (retrieve the washer)
• The 2 bolts (31)
• The bracket (35)
• The 4 bolts (32)
• The plate (33)

Lower the power unit assembly; using the lifting table [0004]

Refitting

Tightening torques

• Engine
• Engine-gearbox assembly mountings
• Exhaust
• Front suspension

Position the lifting bench [0004] with the engine-gearbox assembly at the marks made at removal

Position the engine-gearbox set; using the lifting table [0004]

Refit

• The plate (33)
• The 4 bolts (32)
• The bracket (35)
• The 2 bolts (31)
• Nut (34) and washer
• The 3 support (30) bolts (29)

Remove the tools [0005]

Withdraw the lifting table from under the vehicle

Refit

• The reaction link (37)
• The bolt (38)
• The bolt (36)

Reconnect the reversing lamps connector (on the gearbox)

Reconnect the earth wire (on the gearbox)

Couple the gearbox controls (28)

Adjust the gearbox controls

Refit

• The clutch slave cylinder (15)
• The bolts (39)

Couple the pipe (27) on the vacuum pump vacuum pipe (26) (at "h")

Attach the vacuum pipe (27) (at "j")

Connect to the engine harness

• The pre-post heating relay (22)
• The connector (at "e")
• The engine management ECU (23) (en "f")

Refit - connect to the engine harness: the pneumatic suspension ECU (according to equipment)

Refit the air inlet duct on the air filter (26)

Couple the heater matrix hoses (21)

Clip the engine harness

Connect the fuel supply and return pipes (at "b")

Connect the electrical harness (at "d")

Refit

• The securing clip (at "c")
• The engine fuse box cover (20)
• The pressure take-offs of the exhaust gas pressure sensor
• The lower crossmember (17)
• The power steering fluid reservoir (13) and piping (16) assembly

Couple up

• The power steering pump (19)
• The power steering high pressure pipe (14)
• The power steering pump supply pipe (18)

Tighten the power steering high pressure pipe (18); using tool [4220-T.D / 1603-G]

Remove the tool [4153-T / 1512]

Vehicle with air conditioning

Unclamp the air conditioning compressor (12)

Refit

• The air-conditioning compressor (12)
• The 3 bolts (11)
• The accessories drive belt

Connect the connectors of the air conditioning compressor

Unclamp the air conditioning condenser

Fix the air conditioning condenser on the cooling cassette (7)

Refitting (continued)

Reposition the engine cooling cassette (7)

Refit

• The engine cooling radiator
• The engine turbocharger air cooler
• The cooling cassette (7) fixing bolts
• The engine compartment lower crossmember (6) (according to equipment)
• The bumper crossmember (5)
• The relay box (9)
• The venting unit (1)
• The bonnet opening cable (8)
• The water evacuation pipes (3), (4), (10)
• The air inlet manifold (2)

Couple the exhaust hose on the catalytic converter

Refit

• The exhaust line hangers
• The headlamps
• The front bumper
• The drive shafts avant
• The front splash shields
• The front wheels

Fill the gearbox to the correct level (see the relevant operation)

Fill, bleed and top up the level of the cooling circuit

Top up the engine oil

Reconnect the battery

Checks

Check the operation of the air conditioning (according to equipment)

Carry out

• A road test
• A reading of the auto-diagnostic memories