Installation instructions

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INSTALLATION INSTRUCTIONS: ENGINES, GEARBOXES, AL4 AUTOMATIC TRANSMISSIONS, TURBOS, STEERING BOXES, STEERING PUMPS, AND AIR CONDITIONING COMPRESSORS.

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Installation instructions for engines:

BEFORE YOU START INSTALLING THE ENGINE, WE RECOMMEND THAT YOU FIRST READ THE INFORMATION BELOW.

Check whether the supplied engine corresponds to your original engine, determine the cause of the damage to the original engine and carry out the necessary repairs.
The engine is supplied without oil.
Check all gaskets, hoses, hose clamps and seals and replace them in case of doubt. Recommendations: replace the timing belt and possibly the tensioner, pulleys and the water pump (these parts are not covered by the guarantee).
Check the seals for leaks (these parts are not covered by the guarantee).
Install and check all accessories in accordance with the manufacturer's instructions.
Where possible, use electronic components and wiring harnesses that belong to the car.
Check whether the fuel system is the same brand and type (if necessary move over from the original engine).
For 1.4 and 1.6 HDI engines, the pump and injector numbers must correspond otherwise the injectors must be 'trained' (set up using a test unit) and the pump must be moved over.
Check whether the flywheel is the same (otherwise move over).
Check whether the engine supports correspond to the original engine, otherwise they must be moved over.
Thoroughly clean the parts to be moved over such as the inlet manifold.
Check the exhaust system for dirt (due to the former damage, the catalytic converter - soot filter can be blocked, which can damage the newly to be installed engine), replace in case of doubt.
Turbo engines: ensure that all of the accessories including hoses, intercoolers, etc. are thoroughly clean.
For engines with an immobiliser (diesels), move over the immobiliser or the entire pump.
Replace the oil filter and crankcase plug washer.
Fill all engine fluids in accordance with the manufacturer's instructions (never use old fluid or motor oil) and install new filters.
Take account of the installation and removal instructions in accordance with the manufacturer's information, tightening torques, etc.
Check the cooling system for sufficient flow capacity and ensure that the system is well vented.
Check whether the radiator gets warm everywhere.
Check the operation of the cooling fan.
Check all settings of the engine management system.

The above information is only intended as advice for our customers. No rights can be derived from the information.
The manufacturer's instructions always prevail.

WE RECOMMEND ALLOWING A PROFESSIONAL GARAGE TO INSTALL THE ENGINE.

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Installation instructions for gearboxes:

BEFORE YOU START INSTALLING THE GEARBOX, WE RECOMMEND THAT YOU FIRST READ THE INFORMATION BELOW.

Check whether the supplied gearbox corresponds to your original gearbox, determine the cause of the damage to the original gearbox and carry out the necessary repairs.
Prior to installation, check the flywheel for wear (dual mass flywheels for play - damping).
Check the flywheel for blue spots, these overheated areas can cause vibrations when accelerating.
Check the clutch release arm for deformation - cracks.
Always ensure that all locating dowels are in the gearbox.
Check the engine and gearbox oil seals prior to installation, replace in case of doubt.
Apply grease to the input shaft before installing it.
Never move the oil cooler over from the old gearbox onto the new gearbox, it can contain dirt or metal particles.
Always install an original clutch to avoid rattling and noise from a non-original clutch.
Note: When replacing the guide bush over the input shaft, ensure that you install the filler rings with the new guide bush.
Always check the central bearing and the central bearing support for play and ensure that the outer ring of the central bearing does not turn with the inner ring.
Ensure that when installing the gearbox, the torque converter does not come out of the gearbox otherwise the oil pump will break.
First fasten the gearbox and then the torque converter.
Fasten parts, for instance the torque converter, to the correct tightening torque.
Install the gearbox in accordance with the manufacturer's instructions.
Install drive shafts in accordance with the manufacturer's instructions, also check the boots.
The gear linkage (cables) must be correctly adjusted.
Install a new drain plug washer.
Fill the gearbox in accordance with the dealer specifications (correct oil and quantity).
Seals and clutch parts do not carry a guarantee.
Recommendation: update the transmission computer if necessary.

The above information is only intended as advice for our customers.
No rights can be derived from the information.
The manufacturer's instructions always prevail.

WE RECOMMEND ALLOWING A PROFESSIONAL GARAGE TO INSTALL THE GEARBOX.

Installation instruction for the AL4 automatic transmission:

BEFORE YOU START INSTALLING THE AUTOMATIC TRANSMISSION, WE RECOMMEND THAT YOU FIRST READ THE INFORMATION BELOW.

DRAIN/ FILL/ CHECK THE LEVEL OF THE FLUID

DRAIN
N.B. : Transmission installed; partially drain; approximately 4 litres..

When the automatic transmission fluid is warm: Remove the bolt (1) (hexagon bolt 27 mm).

FILL
INSTRUCTION: Only use Citroën- Peugeot (973622) oil

REMOVE THE PLUG (2)
INSTRUCTION: do not remove the bolt (3).
FILL THE TRANSMISSION

Amount of fluid:
- When changing the fluid: 4 litres
- After removing/ installing the housing of the hydraulic control device: 1.5 litres
- After draining and replacing the hydraulic control device: 4.5 litres
- After draining and replacing the torque converter: 5 litres

CHECK
CONDITIONS
Use the diagnostic tool to check for defects.
Drive the car onto a four-column bridge.
Move the gear lever to P (hand brake released).
With the engine running: Wait until the temperature of the transmission fluid reaches a value between 58° C and 68 °C.

With a running engine: Remove the level plug (4) (19 mm hexagon bolt).
If the fluid runs out in a jet and then starts to drip, the level is ok.
The fluid drips out or no fluid runs out:

Turn off the engine
Allow to cool
Add 0.5 litre of fluid
Repeat the procedure
Always replace: the rubber washer
Tighten the bolt (4) to 2.4 daNm

INSTRUCTION: 0.5 litres of fluid must be added before carrying out the procedure.

The above information is only intended as advice for our customers.
No rights can be derived from the information.
The manufacturer's instructions always prevail.

WE RECOMMEND ALLOWING A PROFESSIONAL GARAGE TO INSTALL THE AUTOMATIC TRANSMISSION.

Installation instructions for turbo chargers:

BEFORE YOU START INSTALLING THE TURBO, WE RECOMMEND THAT YOU FIRST READ THE INFORMATION BELOW.

Check whether the supplied turbo is the correct one for your car.
Check the operation of the turbo pressure sensor.
Remove the oil supply and return lines.
Clean them carefully and check the flow through and the condition of the lines (recommendation: replace the supply line).
Do not use liquid gasket material.
Install a new air filter.
Clean all turbo hoses, the intercooler, if present, and the inlet and exhaust manifolds.
It is important to clean these components to remove any residual metal particles.
Check the crankcase ventilation for dirt and clean if necessary.
Ensure that the catalytic converter and/or sooth filter are not blocked or very dirty.
Replace the oil + filter.
Turn over the engine without starting it (disconnect the diesel injection - ignition) to build up oil pressure. It can take some time before the oil reaches the turbo because the lines have been cleaned.
Allow the engine to idle for several minutes.
Check the oil pressure.
When you know for sure that the turbo is being supplied with sufficient oil, increase the engine speed.
Check the lines and hoses for any leaks.
Check all engine settings.
If necessary, adjust the waste gate.
Retighten the bolts when the engine is warm.

The above information is only intended as advice for our customers.
No rights can be derived from the information.
The manufacturer's instructions always prevail.

WE RECOMMEND ALLOWING A PROFESSIONAL GARAGE TO INSTALL THE TURBO.

Installation instructions for air conditioning compressors:

BEFORE YOU START INSTALLING THE AIR CONDITIONING COMPRESSOR, WE RECOMMEND THAT YOU FIRST READ THE INFORMATION BELOW.

Activities on the air conditioning system must only be carried out by skilled technicians.
If the oil from the old compressor is not extremely clean, it must always be flushed out.
Therefore, always take an oil sample from the old compressor.
The complete air conditioning system must be flushed out if it is contaminated to prevent blockages and wear to the newly to be installed compressor.
Check whether the compressor is filled with oil before installing it.
The filter drier - accumulator must be replaced when installing the new compressor.
The filter drier - accumulator must be installed last.
Then immediately evacuate the system and fill it.
Before filling the air conditioning system, it must be evacuated for at least 30 minutes.
The system must only be filled from the high-pressure side to prevent liquid slugging.
Fill the system with the correct volume of coolant.

The above information is only intended as advice for our customers.
No rights can be derived from the information.
The manufacturer's instructions always prevail.

WE RECOMMEND ALLOWING A PROFESSIONAL GARAGE TO INSTALL THE AIR CONDITIONING COMPRESSOR.

Installation instructions for power steering pump/ unit:

BEFORE YOU START INSTALLING THE POWER STEERING PUMP/ UNIT, WE RECOMMEND THAT YOU FIRST READ THE INFORMATION BELOW.

Before installing the steering unit always check the steering joint and track rods for play.
After installing a mechanical power steering pump, always check that the drive belt is in line.
Note! An electric - hydraulic power steering pump sometimes needs to be trained.
After replacing a power steering pump, steering unit or line, the system must be flushed out.
Only use power steering oil as prescribed by the manufacturer.
Lines rot on the inside and damaging rubber particles or deposits can block the system.
A poorly operating power steering pump:
Steel particles from the pump can cause the seals of a recently installed steering unit to start to leak.
HOW TO CORRECTLY FLUSH OUT A SYSTEM!!!!!!!!!!
After removing the steering unit, place the end of the high-pressure line of the power steering pump in a catch tank.
Fill the reservoir with power steering oil.
Start the engine.
Continue to top up the reservoir with oil until the oil coming from the high-pressure line is clean.
DO NOT LET THE PUMP RUN DRY!
Arrange assistance from a colleague who can continually top up the oil while you start and stop the engine on his direction.
After mounting the steering unit, correctly connect all of the lines (consult the torque values of the manufacturer, tightening the lines too tightly can damage the threads).
Do not connect the return line to the pump yet but put the end into a catch tank.
Refill the pump reservoir with oil.
Start the engine and continue to top up the oil until the oil exiting the system is as clean as the oil you add.
DO NOT LET THE PUMP RUN DRY!
Now install the return line.
Finally vent the system.
While the car is still on the bridge with its wheels unloaded, turn the steering wheel from left to right and back again a number of times (while the engine is running and the reservoir is OPEN).
Then do the same when the wheels are loaded (so when the car is off the bridge).
Top up the oil if necessary.
After aligning the steering, ensure that the boots are still in place.

The above information is only intended as advice for our customers.
No rights can be derived from the information.
The manufacturer's instructions always prevail.

WE RECOMMEND ALLOWING A PROFESSIONAL GARAGE TO INSTALL THE POWER STEERING PUMP/ UNIT.

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