Gearbox removal & installation: Citroen C2 BE4R (DV6TED4)

🧭 Before you start

Fits: platform codes 1.6, HDIF

• Opens: coolant, clutch fluid, gearbox oil

Don't miss

• Use the special tool to counterhold
• Do not disconnect the hydraulic circuit

🔧 Engine codes this applies to

📐 27 workshop diagrams for DV6TED4(9HZ)

Real factory drawings for this job — timing marks, bolt locations and routing. Locked in the free view.

📋 Procedure

Preparation and removal

1. Remove the battery cover
2. Remove the front wheels
3. Remove the left wheel arch liner
4. Remove the engine lower cover
5. Drain the gearbox oil

6. Remove the drive shaft nuts
7. Counterhold tool:
8. Use the special tool to counterhold
9. Ball joint splitting tool:
10. Disconnect the track rod ends
11. Disconnect the lower arm ball joints
12. Lever(s):
13. Use the special tools
14. Disconnect the suspension lower wishbones from the wheel bearing housings
15. Disconnect the drive shafts from the wheel bearing housings
16. Remove the drive shafts from the differential
17. Remove the engine upper cover
18. Remove the air inlet resonator
19. Remove the air duct
20. Remove the engine control unit with bracket
21. Remove the air hose between the inlet manifold and the turbo
22. Remove the battery
23. Remove the power steering control unit
24. Remove the battery tray
25. Disconnect the reversing light switch
26. Disconnect the earth cable from the gearbox
27. Disconnect the electrical wiring from the gearbox
28. Remove the radiator grille
29. Remove the front bumper
30. Disconnect the air hoses from the intercooler
31. Drain the cooling system
32. Disconnect the radiator hoses
33. Disconnect the fan electrical connections
34. Remove the radiator fan bolts
35. Remove the cooling fan
36. Remove the radiator
37. Disconnect the mass airflow meter wiring
38. Without disconnecting the hoses, place the air-conditioning compressor aside
39. All vehicles:
40. Disconnect the exhaust gas pressure sensor hoses
41. Exhaust gas temperature sensor
42. Remove the exhaust gas temperature sensor
43. Heat shield(s):
44. Remove the catalytic converter heat shield(s)
45. Exhaust clamp:
46. Disconnect the exhaust clamp
47. Remove the catalytic converter
48. Remove the diesel particulate filter
49. Remove the exhaust pipe
50. Gearbox support bolt:
51. Remove the bolt
52. Remove the vacuum reservoir
53. Remove the starter motor support
54. Starter motor:
55. Remove the starter motor
56. Unclip the clutch hydraulic line
57. Disconnect the clutch slave cylinder
58. Move the clutch slave cylinder aside
59. Note: Do not disconnect the hydraulic circuit
60. Remove the cross member
61. Remove the exhaust pipe
62. Pendulum support bolts
63. Remove the pendulum support
64. Engine/gearbox attaching bolt:
65. Remove the engine/gearbox lower attaching bolts
66. Fit the special tool to support the engine
67. Disconnect the gear-shift mechanism from the gearbox
68. Engine support:
69. Lower the gearbox slightly
70. Remove the gearbox

Installation and checks

71. Refill the cooling system
72. Bleed the cooling system
73. Stage 1:
74. Stage 2:
75. Reconnect the exhaust gas pressure sensor hose
76. Reconnect the exhaust gas pressure sensor

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