Citroen Xantia

Since 1993 of release

Repair and car operation



Citroen Xantia
+ Introduction
+ The operation manual
+ Routine maintenance
- Engine repair
   + The repair procedures which are not demanding extraction of the engine from the car - petrol engines
   + The repair procedures which are not demanding extraction of the engine from the car - diesel engines
   - Removal and engine major repairs
      Engine major repairs - the general information
      Removal of the power unit - methods and safety measures
      Removal, partition and installation of the power unit - models with РКПП
      Removal, partition and installation of the power unit - models with AT
      Order of dismantling of the engine by its preparation for major repairs carrying out
      Dismantle of a head of cylinders
      Cleaning and check of a condition of a head of cylinders and components клапанного the mechanism
      Assemblage of a head of cylinders
      Removal of shatunno-piston assemblages
      Removal of a cranked shaft
      Cleaning and check of a condition of the block of cylinders/kartera of the engine
      Check of a condition of shatunno-piston assemblages
      Check of a condition of a cranked shaft
      Check of a condition of loose leaves radical and шатунных bearings of a cranked shaft
      Assembly order of the engine after major repairs performance
      Installation of piston rings
      Installation of a cranked shaft and check of working backlashes of radical bearings
      Installation of shatunno-piston groups on the engine and check of working backlashes шатунных bearings
      Initial start of the engine after end of its major repairs
+ Systems of cooling, heating
+ The power supply system and release
+ Engine electric equipment
+ Coupling
+ Transmission
+ Power shafts
+ Uniform hydraulic system
+ Brake system
+ Running gear and steering
+ Body and salon furnish
+ Onboard electric equipment
+ Electric equipment schemes





Removal, partition and installation of the power unit - models with РКПП

Removal

Dismantle of the engine from the car is possible only in gathering with transmission. The partition of the power unit for the purpose of carrying out of major repairs of the engine can be made later.


Fixture of the right support of the power unit (the engine 2.0)


Fixture of the right support of the power unit (the engine 1.8)



 PERFORMANCE ORDER

1. Park the car on an equal horizontal platform with a firm covering so that around there was enough empty seat. Prop up противооткатными boots back wheels, then поддомкратьте redock of the car and establish it on props. Remove both lobbies of a wheel.
2. Lift a cowl in vertical position, then remove the battery, its adjusting pallet and a fixing lath (start and charge Systems see).
3. Open the gate of dump of a regulator of pressure and translate the handle of management of suspension bracket hydraulics in extreme bottom position (LOW) at a corresponding complete set remove protection картера.
4. Remove both power shafts (Power shafts see the Head).
5. Remove a casing of an air cleaner and-or an air inlet sleeve (the Power supply system - petrol models or the Power supply system - diesel models see).
6. Remove the tank of a hydraulic liquid (the Uniform hydraulic system see the Head).
7. Disconnect a cable of gas from the case of a throttle or ТНВД.
8. On petrol models remove the throttle case (the Power supply system - petrol models see).
9. Remove the components established on the left side of a head of cylinders, including the valve of stabilisation of turns of idling.
10. At a corresponding complete set give fixing nuts and shift aside the hydraulic modulator of management ABS. Remove a modulator arm.
11. Liberate soaking up and returnable tubes of hydraulic system (the Uniform hydraulic system) from clamps in a forward part of the engine see the Head and disconnect them from the pump. At once закупорьте the open ends of tubes/unions in order to avoid hit in dirt system.

12. Отболтите a regulator of hydraulic pressure and the distributor of a stream from the forward party of the power unit. Tie up the removed knots a wire to кузовным to elements (the Uniform hydraulic system see the Head). Alternatively, disconnected components can be laid on props.

13. If the engine understands, merge from it engine oil and remove the oil filter (address to the Head Routine maintenance). Carefully wipe, establish into place and strongly tighten a drain stopper.
14. Merge трансмиссионное oil from a transmission (the Manual box of a gear change see). Wipe, screw into place and tighten with demanded effort jellied and drain stoppers (Specifications to the Head Transmission see).
15. Disconnect from a transmission all electroconducting, including brought to the gauge-switch of fires of a backing. Do not forget also about the grounding tyre.
16. Disconnect from РКПП a cable of a drive of a speedometer/electroconducting of the gauge of speed.
17. Hooking a screw-driver with a flat sting, accurately dismember spherical шарнирные connections of draughts of the mechanism of a gear change on a transmission. Take draughts aside from картера РКПП.
18. Remove directing a cable, a metal arm and gauge VMT.

19. In an impellent compartment release clamps of the core and a cable cover on the lever of deenergizing of coupling and a basic arm. Liberate a cable from картера transmissions.

20. Remove the generator (start and charge Systems see).
21. On models with К/В отболтите the compressor also take him aside from the power unit. Tie up the compressor to кузовному to an element, trying not to admit excessive loading on the lines brought to it. At all do not disconnect refrigerator lines (preventions in the Head Routine maintenance see)!
22. Remove a radiator (see the Head of System of cooling, heating). We will notice that the requirement of removal of a radiator is not necessary for all models, however, in all cases allows to expand essentially working space and to reduce to a minimum of damage of the heat exchanger.
23. On petrol models execute following procedures (the Power supply system - petrol models see):
   a) Dump pressure in the power supply system and disconnect hoses of giving and fuel return;
   b) Disunite sockets of electroconducting of the power supply system;
   c) Remove a reception pipe of system of release of the fulfilled gases.
24. On diesel models remove the block of management of preheat (the preheat System - diesel models see) and execute following procedures (the Power supply system - diesel models see):
   a) Disconnect a hose of giving of fuel from assemblage of the fuel filter/casing of the thermostat, also disconnect a returnable hose;
   b) On models with a turbo-supercharging simultaneously with a radiator remove the built in cooler турбокомпрессора;
   c) On engines D6B without a turbo-supercharging remove a casing воздухораспределителя.
25. Release collars and disconnect hoses of the heat exchanger of a heater from the branch pipes on a back partition of an impellent compartment (see the Head of System of cooling, heating).
26. Walk on a plait of electroconducting from the engine to an electric socket (ов) in an impellent compartment. Also walk on a plait to the assembly block of safety locks/relays located near to the battery; disconnect wires.

27. Make sure that all electroconducting is disconnected, and plaits and wires are liberated from intermediate clamps and обвязок and are not capable to prevent extraction of the power unit.

28. Get лебедку into position and connect slings to eyes, привернутым to a head of cylinders. Having included лебедку, hang out the unit on slings.
29. Give the central nut of the left support of the power unit. Remove a washer. Give two nuts of fastening of a support to its arm (besides, do not forget about washers). Take a support from an impellent compartment, then remove the remote plug (if that is provided). For the purpose of expansion of working space, whenever possible, turn out two fixing bolts and remove an arm of a support from a car body.

30. Working under the car, give nuts and bolts of fastening of a rack of a back support to assemblage of a support and a stretcher. Remove a rack.

31. Having released clamps, remove a plastic cover from the top part of assemblage of the right support of the power unit (illustrations Fixture of the right support of the power unit (the engine 2.0 and Fixture of the right support of the power unit (the engine 1.8 see)).

32. Give fixing nuts/bolts and remove a support arm. Take from support assemblage a rubber buffer plate and clean it together with an arm in a reliable place.

33. Make sure that any components and communications does not stir to extraction of the power unit from an impellent compartment. Check up reliability of fixing of such disconnected components, as a rod of a choice of transfers.
34. Lift the power unit and cautiously take it from the car. At unit extraction very much it is useful the help of the assistant as assemblage should be inclined or turned constantly in order to avoid hooks. On the models equipped with system of antiblocking of brakes, try not to damage at unit extraction hydraulic module ABS.
35. Having liberated the unit from an impellent compartment, transfer it through the panel передка the car and lower assemblage on the earth.

Branch of a transmission from the engine

 PERFORMANCE ORDER

1. Establish the power unit taken from the car on pair wooden blocks or a strong workbench.
2. At a corresponding complete set, turn out fixing bolts and remove with картера РКПП a plate of the bottom cover of a flywheel.
3. On models with the exhaust mechanism of a drive of coupling (Coupling see the Head) beat out a fixing finger, or turn out a fixing bolt and remove the lever of deenergizing from the top end of an axis of a plug of deenergizing. Thus there should be a possibility of free rotation of an axis for the purpose of its liberation from выжимного the bearing in the course of branch of a box from the engine. Чертилкой or a marker mark position of the middle of an axis rather картера РКПП (the Manual box of a gear change see).
4. Turn out fixing bolts and remove from a transmission starter assemblage.
5. Check up reliability подпирания the engine and a transmission, then turn out fastening bolts картера boxes to the engine block. Remember adjusting position of each of taken bolts and arms fixed by them and holders. At assemblage all components should be established strictly on former places, in case of need put landing labels.
6. Accurately separate a transmission from the engine. Watch, that the box did not hang all the in weight on a pin of a primary shaft until last definitively will not be liberated from a nave of a conducted disk of coupling.
7. Take from the nests in interfaced surfaces картера the engine or coupling freely planted directing pins and clean them in a reliable place.
8. On models with the exhaust mechanism of a drive of coupling put the second landing marks on картере РКПП, having marked position of a label of a plug вывключения after removal. By means of given to marks the corner under which the plug should refuel into place at assemblage for the purpose of its correct input in gearing with выжимным the bearing is defined.

Installation

 PERFORMANCE ORDER

1. If transmission has been separated from the engine, execute the procedures described in subitem 2-10. Otherwise, pass directly to item 11.
2. Grease with refractory greasing of type Molykote BR2 Plus шлицы a primary shaft of a transmission. Try not to put too much greasing in order to avoid risk of pollution of a conducted disk of coupling.
3. Track correctness of installation of directing pins in nests in interfaced surfaces of the engine or transmission.
4. On models with the exhaust mechanism of a drive of coupling before installation develop выжимной the bearing so that the label in the form of an arrow specified upwards (grooves of a plug of the bearing should appear developed forward on the engine). Achieve combination put in the course of dismantle of a label of an axis of a plug of deenergizing and the second label on картере transmission (the deenergizing plug should appear it is developed under 60 to a surface of a dome of coupling). Such arrangement of components gives a guarantee of correctness of input of a plug in gearing with the bearing.
5. Cautiously bring a transmission to the engine and plant it on directing pins. Watch, that assemblage of a box in all weight did not hang on a pin of a primary shaft after input of last in a nave of a conducted disk of coupling.
6. On models with the exhaust mechanism of a drive of coupling at a definitive joint of the unit track correctness of input in gearing of a plug of deenergizing and выжимного the bearing (the label on a plug should be combined with an original label on картере transmissions (see the Manual box of a gear change).
7. Screw bolts of fastening of a transmission to the engine. Track, that under corresponding bolts the arms removed at dismantle and clamps have been established. Tighten fixture with demanded effort.
8. Establish into place a starter, strongly having tightened bolts of its fastening.
9. On models with the exhaust mechanism of a drive of coupling fix on the top end of an axis of a plug the deenergizing lever. Fix the lever a finger or a bolt (depending on a complete set).
10. At a corresponding complete set establish on the place on картере РКПП a plate of the bottom cover of a flywheel. Strongly tighten fixing bolts.
11. Connect to elevating eyes of the power unit slings лебедки. By means of the assistant hang out assemblage over an impellent compartment of the car.
12. Inclining and turning the unit so that it did not cling to the components located in an impellent compartment, get assemblage on the regular place.
13. Having arranged the power unit in an impellent compartment, establish into place an arm of its right support. Tighten fixing nuts/bolts, while only by hand.
14. If removed, establish on the place on a body of the car an arm of the left support of the power unit. Tighten fixture with demanded effort. Establish a rubber pillow of a support, then screw fixing and central assemblage nuts (do not forget about washers) and slightly them tighten.
15. Working under the car, establish a rack of a back support and screw both bolts of its fastening.
16. Having shaken the unit, achieve its adequate landing to support, then consistently tighten nuts and bolts of all support with demanded effort. Where it is required, after a tightening of nuts of an arm of the right support establish into place the rubber buffer and the bent fixing plate. Tighten with demanded effort bolts of their fastening. Now the elevating rigging can be disconnected from the engine.
17. The further installation is made in an order, the return to a dismantle order. Pay attention to following moments:
   a) Track correctness of a lining and reliability of fastening in intermediate clamps of plaits of electroconducting;
   b) Before introduction of power shafts in transmission differential replace their epiploons (the Manual box of a gear change see);
   c) Track correctness of connection and reliability of fastening of hoses охладительного and heating paths;
   d) do not forget to execute adjustment of a cable of a drive of coupling (Coupling see the Head);
   e) Adjust also a gas cable (the corresponding section of the Head of the Power supply system and release see);
   f) Fill in in the engine and a transmission necessary quantity of oil of a demanded grade (the Manual box of a gear change see).
   g) Fill cooling system (address to the Head Routine maintenance);
   h) On diesel models do not forget to remove air from the power supply system (the Power supply system - diesel models see).


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