Haynes Citroën Diesel Engine Owner's Workshop Manual 1850103798, 9781850103790

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Citroen Diesel Engine Owners

Workshop Mlanual A

K LEGG

rend MIMI

Models covered This manual covers the Citroen 1769 cc and 1905 cc (1.7 & 1.9 litre) Diesel engines used in Visa Saloon, Visa C15 Van and BX models Covers all components exclusive to normally aspirated Diesel engine variants. Does not cover turbocharged Diesel engine introduced May 1988

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Haynes Publishing Group Sparkford

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Somerset BA22 7JJ Englaht Haynes Publications, 861 Lawrence Drive Newbury Park California 91320 USA

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Acknowledgements Certain illustrations are the copyright of Citroen Cars Limited and are used with their permission. Thanks are due to Duckhams Oils who provided lubrication data, Sykes-Pickavant who provided some of the workshop tools, and all the staff at Sparkford who helped in the production of this Manual.

© Haynes Publishing Group 1988 A book in the Haynes Owners

Workshop

Manual

Printed by J.H. Haynes & Co. Ltd, Sparkford, Somerset BA22 7JJ, England

Series

Nr Yeovil,

All rights reserved. No part of this book may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, recording or by any

information storage or retrieval system, in writing from the copyright holder.

without

permission

ISBN 1 85010 379 8 British Library Cataloguing in Publication Data Legg, A. K. (Andrew K.), 7942Citroen diesel engine owners workshop manual 1. Cars, maintenance & repair. Amateurs’ manuals |. Title Il. Series

629.28'722 ISBN 1-85010-379-8 Whilst every care is taken to ensure that the information in this manual is correct, no liability can be accepted by the authors or publishers for loss, damage or injury caused by any errors in, or omissions from, the information given.

Contents Introductory

pages

About this manual Introduction to the Citroén 1.7 and 1.9 diesel engines General dimensions, weights and capacities Jacking (Visa Saloon models) Buying spare parts General repair procedure Tools and working facilities Conversion factors Safety first! Routine maintenance Recommended lubricants and fluids Fault diagnosis

5 5 6 7 7 8 8 11 i\22 13 18 19

Chapter 1 Engine

22

Chapter2 Cooling system

78

Chapter3 Fuel and exhaust systems

85

Chapter4 Clutch, transmission and driveshafts

107

Chapter5 Braking and hydraulic systems

115

Chapter6 Suspension and steering

121

Chapter7 Electrical system

125

Index

144

Front three-quarter view of Citroén XUD 7

Oi filler cap and ventilation

Diagnostic socket Temperature sensors DAN Nom Fast idle thermo unit

Thermostat cover Injection pump (Roto-Diese/) 9 Coolant hose to oil cooler 10 Drivebelt tension adjusting

engine. Timing 12 73 14 15 16 17

belt cover has been

Alternator Oil filler Sump Alternator drivebelt Crankshaft pulley Water pump

removed

Timing belt intermediate Injection pump sprocket Timing belt tensioner Right-hand engine mounting ‘bracket

Camshaft sprocket

About

this manual

Its aim The aim of this manual is to help you get the best value from your vehicle. It can do so in several ways. It can help you decide what work must be done (even should you choose to get it done by a garage), provide information on routine maintenance and servicing, and give a logical course of action and diagnosis when random faults occur. However, it is hoped that you will use the manual by tackling the work yourself. On simpler jobs it may even be quicker than booking the car into a garage and going there twice, to leave and collect it. Perhaps most important, a lot of money can be saved by avoiding the costs a garage must charge to cover its labour and overheads.

The manual has drawings and descriptions to show the function of the various components so that their layout can be understood. Then the tasks are described and photographed in a step-by-step sequence so that even a novice can do the work.

It is freely illustrated, especially in those parts where there is a detailed sequence of operations to be carried out. There are two forms of illustration: figures and photographs. The figures are numbered in sequence with decimal numbers, according to their position in the Chapter — eg Fig. 6.4 is the fourth drawing/illustration in Chapter 6. Photographs carry the same number (either individually or in related groups) as the Section or sub-section to which they relate. There is an alphabetical index at the back of the manual as well as a contents list at the front. Each Chapter is also preceded by its own individual contents list. References to the ‘left’ or ‘right’ of the vehicle are in the sense of a person in the driver's seat facing forwards. However, in Chapter 1, references to the ‘front’ of the engine are in respect of the timing belt end with the engine removed from the vehicle. Unless otherwise stated, nuts and bolts are removed anti-clockwise, and tightened by turning clockwise.

Unlike most Haynes manuals, which cover a particular vehicle in different trim levels and engine sizes, this book covers one engine and its associated equipment as fitted to a range of vehicles. Items which are common to Diesel and petrol models — eg bodywork, transmission and running gear — are not covered in this book.

by turning

Vehicle manufacturers continually make changes to specifications and recommendations,

and these, when notified, are incorporated into

Our manuals at the earliest opportunity.

Project vehicles /ts arrangement

The vehicles used in the preparation of this manual, and which appear in many of the photographs, were a BX Diesel and a Visa Diesel.

The manual is divided into seven Chapters, each covering a logical sub-division of the vehicle. The Chapters are each divided into Sections, numbered with single figures, eg 5; and the Sections into paragraphs (or sub-sections), with decimal numbers following on from the Section they are in, eg 5.1, 5.2, 5.3 etc.

Whilst every care is taken to ensure that the information in this manual is correct, no liability can be accepted by the authors or publishers for loss, damage or injury caused by any errors in, or omissions from, the information given.

Introduction

the

Citroén

to

1.7 and

1.9 diesel engines

The Citroén diesel engines covered in this manual were first fitted to BX models in early 1984 and subsequently fitted to Visa models in early 1985. They are built at the highly automated Citroen factory at Tremery in France and are given the code names of XUD 7 for the 1.7 and XUD 9 for the 1.9.

Compared with petrol engines of similar capacity the diesel version

is extremely quiet on the road, only a certain amount of clatter at idle betraying its presence to the driver. Routine maintenance tasks are few and easily carried out, but work on the fuel injection pump will require the use of two dial test indicators.

Outside the engine bay the vehicles to which these engines are fitted are much the same as petrol-engined versions. For complete coverage of a particular vehicle, the appropriate manual for petrol engined vehicles will be needed as well.

General dimensions, weights and capacities Dimensions Overall length: Visa: Sal OOM BR esos ee terete ae cae «cc eter sae ais ea Marites vee:

Viel eee Sates 208 Semen PO Nao B Xs, asst beer Meeenemas sae ee eres

Oe ne dod t ras WSocans dee RR Pe ae Pe le dies cients

ee cc

Overall width: Visa: SOOM etecers taste cere eee ces ees she keener cn oe oan seseuree eran eae MEAN ipcep deetuesirs oat eee chew, atenn ans ar acer non ae es nae ee ek ea Oe

BX esceg s icztv ee aN RG

ea ene

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Overall height Visa: Sal ihccoteemertre ser onto

ees ta aoe a een «re, rae ey eI VAIN: 3 san. eae ee aac sa ace a eli ee cere oO A eceR BX scscistehiss b Ree RT cea te Stine, ice Re Re ee, RA

3.725 m (146.7 in) 3.995 m (157.3 in) 4.230 m (166.5 in)

1.526 m (60.1 in) 1.636 m (64.4 in) 1.660 m (65.4 in)

1.410 m (55.5 in) 1.801 m (70.9 in) 1.360 m (53.5 in)

te

Wheelbase:

VISA Lgcxcpun cadences geete nn eee oy Ot ooh, eh RUN EN te eee TMs Ay BX cisws aseaschseaetenys Ae ee ROME oie ema oe aeRee ace SO i Pic gee Ms, BR

2.420 m (95.3 in) 2.66 m (104.7 in)

Weights Kerb weight: Visa: SAIOOMN iebsecivenadice esd See eee ea, ene er Viaihig.gstaviertgvesact Sane ern ARO Sete eae eae See, BX trae ties ceteris adh saga eee eet ie ee ee I eae Noo,

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