Citroën Xantia

since 1993 release

Repair and operation of the car



Citroën Xantia
+ Introduction
+ Operation manual
+ Routine maintenance
- Repair of the engine
   + 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 capital repairs of the engine
      Capital repairs of the engine - the general information
      Removal of the power unit - methods and precautionary measures
      Removal, partition and installation of the power unit - model with RKPP
      Removal, partition and installation of the power unit - model with AT
      Order of dismantling of the engine by preparation it to carrying out capital repairs
      Dismantle of a head of cylinders
      Cleaning and check of a condition of a head of cylinders and components of the valvate mechanism
      Assembly of a head of cylinders
      Removal of conrod and piston assemblies
      Removal of a bent shaft
      Cleaning and check of a condition of the block of cylinders/case of the engine
      Check of a condition of conrod and piston assemblies
      Check of a condition of a bent shaft
      Check of a condition of inserts of radical and conrod bearings of a bent shaft
      Engine assembly order after performance of capital repairs
      Installation of piston rings
      Installation of a bent shaft and check of working gaps of radical bearings
      Installation of conrod and piston groups on the engine and check of working gaps of conrod bearings
      Initial start of the engine after completion of its capital repairs
+ Cooling systems, heating
+ Power supply system and release
+ Engine electric equipment
+ Coupling
+ Transmission
+ Power shafts
+ Uniform hydraulic system
+ Brake system
+ Running gear and steering
+ Body and finishing of salon
+ Onboard electric equipment
+ Schemes of electric equipment


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Removal, partition and installation of the power unit - model with RKPP

Removal

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


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


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



 PERFORMANCE ORDER

1. Park the car on the flat horizontal platform with a hard coating so that around remained rather empty seat. Prop up antiretractable boots back wheels, then a front of the car and establish to a poddomkratta it on props. Remove both forward wheels.
2. Lift a cowl in vertical position, then remove the battery, its adjusting pallet and a fixing level (see Systems of start and a charge).
3. Open the gate of dumping of the regulator of pressure and transfer the handle of management of suspension bracket hydraulics to extreme lower situation (LOW) at the corresponding complete set remove protection of a case.
4. Remove both power shafts (see the Head Power shafts).
5. Remove a casing of the air cleaner and/or a sleeve of an air inlet (see the Power supply system - petrol models or the Power supply system - diesel models).
6. Remove the tank of hydraulic liquid (see the Head Uniform hydraulic system).
7. Disconnect a gas cable from the case of a throttle or TNVD.
8. On petrol models remove the throttle case (see the Power supply system - petrol models).
9. Remove the components installed on the left side of a head of cylinders including the valve of stabilization of turns of idling.
10. At the corresponding complete set give fixing nuts and shift the hydraulic modulator of management of ABS aside. Remove a modulator arm.
11. Release the soaking-up and returnable tubes of hydraulic system (see the Head Uniform hydraulic system) from clamps in a forward part of the engine and disconnect them from the pump. At once to a zakuporta the open ends of tubes/unions in order to avoid hit in system of dirt.

12. Otboltite the 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 body elements (see the Head Uniform hydraulic system). Alternatively, the disconnected components can be laid on props.

13. If the engine understands, merge from it engine oil and remove an oil filter (address the Head Routine maintenance). Carefully wipe, establish into place and strongly tighten a drain stopper.
14. Merge gearbox oil from the transmission (see. Manual box of gear shifting). Wipe, screw into place and tighten with the required effort jellied and drain traffic jams (see Specifications to the Head Transmissiya).
15. Disconnect from the transmission all electrical wiring, including brought to the sensor switch of fires of a backing. Do not forget also about the grounding tire.
16. Disconnect from RKPP a drive cable a speed sensor speedometer/electrical wiring.
17. Hooking the screw-driver with a flat sting, accurately dismember spherical hinged connections of drafts of the mechanism of gear shifting on the transmission. Take drafts aside from RKPP case.
18. Remove a cable guide, a metal arm and the VMT sensor.

19. In a motive compartment release clamps of the core and a cover of a cable on the lever of switching off of coupling and a basic arm. Release a cable from a transmission case.

20. Remove the generator (see Systems of start and a charge).
21. On models with In an otboltita the compressor also take him aside from the power unit. Tie up the compressor to a body element, trying not to allow excessive load of the lines brought to it. Do not disconnect refrigerator lines at all (see preventions in the Head Routine maintenance)!
22. Remove a radiator (see the Head of the Cooling system, heating). Let's notice that the requirement of removal of a radiator is not necessary for all models, however, in all cases allows to expand significantly working space and to minimize damages of the heat exchanger.
23. On petrol models perform the following procedures (see the Power supply system - petrol models):
   a) Dump pressure in a power supply system and disconnect hoses of giving and return of fuel;
   b) Disunite power supply system electrical wiring sockets;
   c) Remove a reception pipe of system of production of the fulfilled gases.
24. On diesel models remove the control unit of preheat (see System of preheat - diesel models) and perform the following procedures (see the Power supply system - diesel models):
   a) Disconnect a hose of supply of fuel from assembly of the fuel filter / casing of the thermostat, also disconnect a returnable hose;
   b) On models with a turbo-supercharging along with a radiator remove the built-in cooler of a turbocompressor;
   c) On D6B engines without turbo-supercharging remove an air distributor casing.
25. Release collars and disconnect heater heat exchanger hoses from the branch pipes on a back partition of a motive compartment (see the Head of the Cooling system, heating).
26. Walk on an electrical wiring plait from the engine to the electric socket(s) in a motive compartment. Also walk on a braid to the assembly block of safety locks/relay located near the battery; disconnect wires.

27. Make sure that all electrical wiring is disconnected, and plaits and wires are released from intermediate clamps and bindings and are not capable to interfere with extraction of the power unit.

28. Start the winch into position and connect slings to eyes, privernuty to a head of cylinders. Having turned on the winch, 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 a motive 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 a support arm from a car body.

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

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

32. Give fixing nuts / bolts and remove a support arm. Take a rubber buffer plate from assembly of a support and move away her together with an arm to the reliable place.

33. Make sure that does not interfere any components and communications with extraction of the power unit from a motive compartment. Check reliability of fixing of such disconnected components as a rod of the choice of transfers.
34. Lift the power unit and carefully take it from the car. At extraction of the unit the help of the assistant as assembly should be inclined or turned constantly in order to avoid hooks very much is useful. On the models equipped with system of anti-blocking of brakes try not to damage the hydraulic ABS module at extraction of the unit.
35. Having released the unit from a motive compartment, transfer it via the panel of a front of the car and omit assembly on the earth.

Separation of the transmission from the engine

 PERFORMANCE ORDER

1. Install the power unit taken from the car on pair of wooden blocks or a strong workbench.
2. At the corresponding complete set, turn out fixing bolts and remove a plate of the lower cover of a flywheel from RKPP case.
3. On models with the exhaust mechanism of the drive of coupling (see the Head Stsepleniye) beat out a fixing finger, or turn out a fixing bolt and remove the switching off lever from the top end of an axis of a fork of switching off. At the same time there has to be a possibility of free rotation of an axis for the purpose of its release from the release bearing in the course of separation of a box from the engine. With Chertilka or a marker mark position of the middle of an axis concerning RKPP case (see. Manual box of gear shifting).
4. Turn out fixing bolts and remove assembly of a starter from the transmission.
5. Check reliability of supporting of the engine and transmission, then turn out bolts of fastening of a case of a box to the engine block. Remember the adjusting provision of each of the taken bolts and arms fixed by them and holders. At assembly all components have to be installed strictly on former places, in case of need put landing tags.
6. Accurately separate the transmission from the engine. You watch that the box did not hang all the it is powerful on a pin of a main shaft until the last finally is not released from a nave of the conducted clutch plate.
7. Take from the nests in the interfaced surfaces of a case of the engine or coupling freely put directing pins and move away them to the reliable place.
8. On models with the exhaust mechanism of the drive of coupling put the second landing marking on RKPP case, having marked the provision of a tag of a fork of a vyvklyucheniye after removal. With the help to this marking the corner under which the fork has to refuel into place at assembly for the purpose of its correct input in gearing with the release bearing is defined.

Installation

 PERFORMANCE ORDER

1. If transmission was separated from the engine, perform the procedures described in subitem 2 — 10. Otherwise, you pass directly to item 11.
2. Grease with refractory lubricant like Molykote BR2 Plus of a vent of a main shaft of the transmission. Try not to apply too much lubricant in order to avoid risk of pollution of the conducted clutch plate.
3. Track correctness of installation of guides of pins in nests in the interfaced surfaces of the engine or transmission.
4. On models with the exhaust mechanism of the drive of coupling before installation deploy the release bearing so that the tag in the form of an arrow specified up (grooves of a fork of the bearing have to be developed forward on the engine). Achieve combination put in the course of dismantle of a tag of an axis of a fork of switching off and the second tag on a transmission case (a fork of switching off have to it is developed under 60 ° to a coupling dome surface). Such arrangement of components gives a guarantee of correctness of input of a fork in gearing with the bearing.
5. Carefully bring the transmission to the engine and put it on the directing pins. You watch that assembly of a box all weight did not hang on a pin of a main shaft after input of the last in a nave of the conducted clutch plate.
6. On models with the exhaust mechanism of the drive of coupling at a final joint of the unit track correctness of input in gearing of a fork of switching off and the release bearing (the tag on a fork has to be combined with an original tag on a transmission case (see. Manual box of gear shifting).
7. Screw bolts of fastening of the transmission to the engine. Track that under the corresponding bolts the arms and clamps removed at dismantle were established. Tighten fixture with the required effort.
8. Establish into place a starter, having strongly tightened bolts of its fastening.
9. On models with the exhaust mechanism of the drive of coupling fix the switching off lever on the top end of an axis of a fork. Fix the lever by a finger or a bolt (depending on a complete set).
10. At the corresponding complete set establish on the place on RKPP case a plate of the lower cover of a flywheel. Strongly tighten fixing bolts.
11. Connect winch slings to lifting eyes of the power unit. By means of the assistant hang out assembly over a motive compartment of the car.
12. Inclining and turning the unit so that it did not cling to the components located in a motive compartment, start assembly on the regular place.
13. Having arranged the power unit in a motive compartment, establish into place an arm of its right support. Tighten fixing nuts / bolts, so far only by hand.
14. If removed, establish on the place on a car body an arm of the left support of the power unit. Tighten fixture with the required effort. Establish a rubber pillow of a support, then screw fixing and central assembly nuts (do not forget about washers) and slightly tighten them.
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 adequate landing it on support, then consistently tighten nuts and bolts of all support with the required effort. Where it is required, after tightening of nuts of an arm of the right support install into place the rubber buffer and a curved fixing plate. Tighten bolts of their fastening with the required effort. Now the lifting rigging can be disconnected from the engine.
17. Further installation is made as it should be, the return to a dismantle order. Pay attention to the next moments:
   a) Track correctness of laying and reliability of fastening in intermediate clamps of plaits of an electrical wiring;
   b) Before introduction of power shafts to differential of the transmission replace their epiploons (see. Manual box of gear shifting);
   c) Track correctness of connection and reliability of fastening of hoses of cooling and heating paths;
   d) Do not forget to execute adjustment of a cable of the drive of coupling (see the Head Stsepleniye);
   e) Adjust also a gas cable (see appropriate section of the Head of the Power supply system and release);
   f) Fill in necessary amount of oil of the required grade in the engine and the transmission (see. Manual box of gear shifting).
   g) Fill the cooling system (address the Head Routine maintenance);
   h) On diesel models do not forget to remove air from a power supply system (see the Power supply system - diesel models).


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