Peugeot 308: Removing - refitting : Hybrid double-clutch piloted manual gearbox

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 :

• Insulation bag
• Workshop jack
• Workshop crane
• Shackle
• Lifting chain

Tool	Reference	Description
	[0188-AQ]	Lifting ring

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.

ESSENTIAL : Switch the vehicle’s power off .

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

Remove :

• The front wheels
• The front mud guards
• The under-engine protector
• The front bumper
• The front bumper lower frame
• The front left subframe extension
• The style cover

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

Drain the hybrid drive train cooling circuit .

EDCT TYPE GEARBOX 6 SPEED AND HYBRID 6-SPEED PILOTED MANUAL GEARBOX

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 traction battery cooling circuit coolant pump
• The turbocharger cooling electric coolant pump
• The coolant outlet housing

3. Removing

Uncouple the pipes (1), (2) from the heating unit .

Unclip the connector  (In "a") .

Disconnect the connector  (In "b") .

Disconnect :

• The connector  (In "c") 
• The connectors  (At "e" and "f") 

Unclip the electrical harness  (In "d") .

CAUTION : Under the vehicle.

Uncouple the hybrid drive train cooling circuit pipe ‎(3).

Remove the bolt (4).

Unfasten the earth cable (5) (In "g") .

Unclip the hybrid drive train cooling circuit pipe ‎(6) (In "h") .

Remove :

• The bolt (8)
• The clip (9)

Uncouple and move aside the internal combustion engine ‎ and hybrid drive train cooling pipes ‎(7) (In "j") .

Unclip the electrical harness  (In "k") .

Remove :

• The bolts (10) and (12)
• The plate (11)

Remove the bolts (13).

Remove the bolts (14).

CAUTION : From above the vehicle.

Unclip then move aside the protector  (In "l") .

Remove the 2 nuts (16).

Move aside the electrical power harness (15).

ESSENTIAL : Place the electrical power harness (15) in an insulating bag (In "m") .

Support the engine - hybrid dual-clutch piloted manual gearbox assembly ; Using a workshop hoist and a wooden block.

Remove :

• The bolts (18) and (19)
• The flexible mounting (17)

Remove :

• The bolts (20) and (22)
• The flexible mounting (21)

CAUTION : Risk of breaking the lifting eye (at "n") ; Lift the hybrid double-clutch piloted manual gearbox by its two lifting points (at "n" and "p").

Position the shackles (at "n").

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

Support the hybrid dual-clutch piloted manual gearbox ; Using a workshop crane (at "n" and "p").

Remove the nuts (23).

Move aside the hybrid dual-clutch piloted manual gearbox.

Remove the hybrid dual-clutch piloted manual gearbox.

4. Refitting

CAUTION : Observe the tightening torques.

EDCT TYPE GEARBOX 6 SPEED AND HYBRID 6-SPEED PILOTED MANUAL GEARBOX

Tightening torques :

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

Precautions to be taken before refitting :

• Check that centring pins (25) are present
• Check that the centring stud ‎24 is present

Draw the hybrid dual-clutch piloted manual gearbox near and direct it so as to position it opposite the centring rings ‎(25) and its centring studs (24).

Refit :

• The nuts (23)
• The bolts (14)

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

Remove :

• The shackle  (In "n") 
• The lifting eye [0188-AQ] (In "p") 

Refit :

• The flexible mounting (21)
• The bolts (20) and (22)
• The flexible mounting (17)
• The bolts (18) and (19)

Remove the insulating bag ‎ (In "m") .

Refit :

• The electrical power harness (15)
• The 2 nuts (16)

Reclip the protector  (In "l") .

Refit :

• The bolts (14)
• The bolts (13)
• The plate (11)
• The bolts (10) and (12)

Clip the electrical harness  (In "k") .

Couple the internal combustion engine ‎ and hybrid drive train cooling pipes ‎(7) (In "j") .

Refit :

• The clip (9)
• The bolt (8)

Clip on the hybrid drive train cooling circuit pipe (6) (In "h") .

Couple the hybrid drive train cooling circuit pipe ‎(3).

Refit :

• The earth cable (5) (In "g") 
• The bolt (4)

Reconnect :

• The connector  (In "c") 
• The connectors  (At "e" and "f") 

Clip :

• The electrical harness  (In "d") 
• The connector  (In "a") 

Reconnect the connector  (In "b") .

Couple up the pipes (1), (2) of the heating unit .

5. Additional operations

EDCT TYPE GEARBOX 6 SPEED AND HYBRID 6-SPEED PILOTED MANUAL GEARBOX

Refit :

• The coolant outlet housing
• The ancillaries battery and its support
• The direct voltage converter
• The air filter housing
• The front driveshafts
• The traction battery cooling circuit coolant pump
• The turbocharger cooling electric coolant pump
• The front subframe
• The exhaust flexible hose

Refit :

• The front left subframe extension
• The front bumper lower frame
• The front bumper
• The under-engine protector
• The front mud guards
• The front wheels
• The style cover

ESSENTIAL : Switch the vehicle’s power on .

Perform the following operations with the diagnostic tool :

• Downloading the hybrid double-clutch piloted manual gearbox ECU
• Downloading of the electric drive machine ECU
• Replacing the hybrid double-clutch piloted manual gearbox

Fill and bleed the hybrid drive train cooling circuit .

Check the oil level in the hybrid double-clutch piloted manual gearbox .

6. Check

Check :

• There is no noise
• The circuits are free from leaks

Carry out a road test.