Peugeot 205 - Manual (Page 80)

twisting them anti-clockwise and disconnect
the connectors. Also, where applicable, trace
the harness lead(s) back to the relay box,
situated beside the battery. Unclip the wiring
connector plate from the front of the relay box
cover, then undo the retaining nut and remove
the cover. Lift up the engine harness lead
cover; then undo the nut(s) and release the
lead(s) from the relay box. Check that all the
relevant connectors have been disconnected,
and that the wiring is released from any
relevant clips or ties, so that it is free to be
removed with the engine/transmission. Where
it is not possible to separate the harness at
the main connectors, make careful notes and
disconnect all individual wiring connectors
attached to the engine and transmission.
17 Manoeuvre the engine hoist into position,
and attach it to the lifting brackets bolted to
the engine. Raise the hoist until it is
supporting the weight of the engine.
18 On XU and TU series engines from
underneath the vehicle, slacken and remove
the nuts and bolts securing the rear engine
mounting link to the mounting assembly and
subframe, and remove the link. On all models,
undo the nuts/bolts securing the left-hand
and right-hand engine mounting brackets to
the engine and mountings, and remove the
brackets and mountings as necessary.
19 Make a final check that any components
which would prevent the removal of the
engine/transmission from the car have been
removed or disconnected. Ensure that
components such as the gearchange selector
rod are secured so that they cannot be
damaged on removal.
20 Slowly and methodically 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.
21 Once the engine is high enough, lift it out
over the front of the body, and lower the unit
to the ground (see illustration).
Separation
22 With the engine/transmission assembly
removed, support the assembly on suitable
blocks of wood, on a workbench (or failing
that, on a clean area of the workshop floor).
XV, XW and XY series engines
23 Unscrew and remove the flywheel
housing-to-engine connecting bolts and nuts.
24 There are thirteen bolts and two nuts
altogether. Note that an engine lifting lug and
earth strap are fitted under some of the bolts.
25 Refer to Chapter 6 and remove the clutch
assembly, ignoring any procedures that have
already been carried out as part of the
engine/transmission removal sequence.
26 Unbolt and remove the flywheel (Chap-
ter 2A), then slacken and remove the retaining
bolts, and remove the starter motor.
27 Unscrew and remove the two bolts and
the nut close to the crankshaft oil seal (see
illustration).
28 Unscrew the engine-to-transmission
flange connecting bolts. Unbolt the right-hand
rear engine mounting.
29 Unscrew and remove the crankshaft
pulley nut. In order to hold the crankshaft
against rotation, temporarily screw in two
bolts into the holes in the flywheel mounting
flange and place a long lever between them.
30 Remove the crankshaft pulley.
31 Remove the rocker cover.
32 Remove the timing chain cover and
extract the fuel pump operating plunger (see
illustration).
33 Unscrew and remove the remaining
connecting bolts and nuts which are located
on the final drive casing side near the
driveshaft oil seals.
34 Using a length of wood, prise the engine
and transmission apart (see illustration).
XU and TU series engines
35 Undo the retaining bolts, and remove the
flywheel lower cover plate (where fitted) from
the transmission.
36 Slacken and remove the retaining bolts,
and remove the starter motor from the
transmission.
37 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.
38 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 plate.
39 If they are loose, remove the locating
dowels from the engine or transmission, and
keep them in a safe place.
Reconnection
XV, XW and XY series engines
40 If removed, check that the oil pump
pick-up strainer is in position within the
transmission casing.
2D•6 Engine removal and overhaul procedures
3.32 Removing the timing chain cover 3.34 Separating the engine from the
transmission
3.21 Removing the engine and manual
transmission
3.27 Remove the two bolts and nut close
to the crankshaft oil seal - XV, XW and XY
series engines