Peugeot 308: Removing - refitting : Engine - hybrid dual-clutch piloted manual gearbox assembly

Peugeot 308 2021-2024 (P5) Service Manual / Mechanical :: Engine / Engine assembly / Removing - refitting : Engine - hybrid dual-clutch piloted manual gearbox assembly

ESSENTIAL : Observe the safety and cleanliness recommendations .

ESSENTIAL : All personnel carrying out work on a vehicle fitted with traction batteries must have received specific electric vehicle training and be authorised to work on these vehicles (observe the regulations in force in the respective country).

1. Tooling

Workshop equipment :

Lifting chains
Workshop crane
Strap
Shackles

Tool	Reference	Description
	[0004-Z][WE-160002-A]	lifting table
	[0005-C][EN-52055]	set of retaining supports (right-hand)
	[0005-G][EN-52055]	set of retaining supports (right-hand)
	[0194-T] (*)	Set of plugs
	[0188-AQ]	Lifting ring
	[0102-M] (*)	Snap hook
(*) Use standard workshop equipment if the special tool is not available

2. Preliminary operations

ESSENTIAL : Observe the safety and cleanliness recommendations specific to (THP) petrol direct injection engines .

Place the vehicle on a 2-post lift.

Strap the vehicle on the 2-post lift.

ESSENTIAL : Switch the vehicle’s power off .

CAUTION : Cover the openings of the air inlet circuit .

ESSENTIAL : Wait at least one hour before carrying out any work on the exhaust system and turbocharger.

Remove :

The front wheels
The front mud guards
The under-engine protector
The front bumper
The front bumper lower frame
Front subframe extensions
The style cover

CAUTION : Do not drain the hybrid dual-clutch piloted manual gearbox.

Drain the hybrid drive train cooling circuit (depending on equipment).

Remove :

The ancillaries battery and its support
The direct voltage converter
The air filter housing
The front driveshafts
The exhaust flexible hose
The front subframe
The ancillary drive belt

ESSENTIAL : Remove the electric power cable ‎ (Traction battery side).

N.B. : Secure the exhaust line to the body of the vehicle.

3. Removing

Slacken the clips (1).

Release :

The air inlet union (2)
The air outlet union (3)

Slacken the clip (4) (depending on equipment).

Move aside the air outlet union (3) (depending on equipment).

Remove :

The bolts (5)
The air inlet union (2) (In the direction of the arrow )
The air outlet union (3) (In the direction of the arrow )

N.B. : When uncoupling the fuel pipe (6), use a cloth to protect yourself from any splashes of fuel.

Unclip the clips (at "a").

Uncouple :

The fuel supply pipe (6)
The fuel vapours pipe (7)

N.B. : Block the apertures of the high pressure fuel pump ; Using the plugs [0194-T].

Uncouple the fuel vapours recirculation pipe (at "b").

Remove :

The bolt (9)
The air inlet union (8)

Uncouple the pipes (10), (11) from the heating unit .

Unclip the connector (at "c").

Disconnect the connector (at "d").

Disconnect :

The connector (at "e")
The connector (at "g", "h")

Unclip the electrical harness (at "f").

Uncouple the breather pipe (13) (at "k").

Unclip the clip (at "j").

Uncouple the coolant outlet housing pipe (12).

N.B. : Under the vehicle.

Uncouple the hybrid drive train cooling circuit pipe ‎(14).

Remove :

The bolt (15)
The earth cable (16) from the gearbox

Unfasten the earth cable (16) (at "l").

Uncouple the hybrid drive train cooling circuit pipe ‎(17) (at "m").

CAUTION : Make sure you don’t bend the air-conditioning pipes.

Move aside and clamp the air conditioning compressor (without opening the air conditioning fluid circuit).

Uncouple the hybrid drive train cooling circuit pipe ‎(18).

Uncouple the hybrid drive train cooling circuit pipe ‎(19).

Position (front surface) :

The support [0005-C / EN-52055] (at "p", "q")
The support [0005-G / EN-52055] (at "n")

Position (rear side) :

The support [0005-G / EN-52055] (at "r")
The support [0005-G/ EN-52055] (at "s")

Slightly lift the lifting bench [0004-Z/ WE-160002-A] to put the engine/gearbox assembly under tension.

N.B. : Make marks on the ground to reference the position of the power train.

Remove the 4 bolts (20).

Remove the 2 bolts (21).

CAUTION : Check that there is no fouling between the engine - hybrid dual-clutch piloted manual gearbox assembly and the body.

Remove the engine - hybrid dual-clutch piloted manual gearbox from underneath the vehicle (Carefully).

4. Engine - hybrid dual-clutch piloted manual gearbox assembly slinging procedure

CAUTION : Prohibition on slinging (at "u") to remove the engine - hybrid dual-clutch piloted manual gearbox assembly.

Position the shackles (at "t").

Screw in the lifting ring [0188-AQ] (at "v").

Support the engine - hybrid dual-clutch piloted manual gearbox assembly ; Using the workshop hoist and the lifting chain (at "t", "v").

Remove tools [0005-C / EN-52055] and [0005-G / EN-52055].

Disengage the lifting bench [0004-Z/ WE-160002-A].

Put the engine - hybrid dual-clutch piloted manual gearbox assembly on the ground.

Detach the workshop hoist and the lifting chain from the engine - hybrid dual-clutch piloted manual gearbox assembly.

5. Stripping

Remove :

The traction battery cooling circuit coolant pump
The turbocharger cooling electric coolant pump
The electrical power harness
The catalytic converter

6. Slinging of the hybrid dual-clutch piloted manual gearbox

Position the snap hook [0102-M] (at "u").

Position the shackles (at "t").

Support the engine ; Using the workshop hoist and the lifting chain (at "t", "u").

Screw in the lifting ring [0188-AQ] (at "v").

Position the shackles (at "w").

Support the hybrid dual-clutch piloted manual gearbox ; Using the workshop hoist and the lifting chain (at "v", "w").

Remove the bolts (22).

Remove the bolts (23).

Unclip the electrical harness (at "x").

Remove :

The bolts (24), (26)
The plate (25)

Remove the nuts (27).

Move aside the hybrid dual-clutch piloted manual gearbox.

Remove the hybrid dual-clutch piloted manual gearbox.

7. Refitting

CAUTION : Observe the tightening torques.

Tightening torques :

Engine
Engine/hybrid dual-clutch piloted manual gearbox coupling
Electrical equipment (under bonnet)
Engine - hybrid dual-clutch piloted manual gearbox assembly mountings
Exhaust line
Front suspension
Wheels

Precautions to be taken before refitting :

Check that centring pins (29) are present
Check that the centring stud ‎(28) is present

Draw the hybrid dual-clutch piloted manual gearbox near and direct it so as to position it opposite the centring rings ‎(29) and its centring studs (28).

Refit :