Haynes Citroën Diesel Engine Owners Workshop Manual 1850109648, 9781850109648

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EDINBURGH CITY LIBRARIES Din’

s< EDINBURGH CITY LIBRARIES Reference Department q THIS

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Citroen Diesel - Engine Owners Workshop Manual AK

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Models covered This manual covers the Citroén 1769 cc and 1905 cc (1.7 and 1.9 litre) Diesel engines used in the Visa,

C15/Champ Van and BX models (including the 1.7 litre turbocharged engine used in the BX) Does not cover specific application to Xantia models (1379-3W3)

‘RU 0011

Haynes Publishing Sparkford Nr Yeovil Somerset BA22 7JJ England Haynes Publications, Inc 861 Lawrence Drive Newbury Park California 91320 USA

ABCD

,, .

Restoring and Preserving our

Motoring,Heritage ae -

§

Few people can hi; ad the luck to realise their dreams to quite the same extent aridi ich a remarkable fashion as John Haynes, Founder and Chairman of the Haynes Publishing Group. Since 1965 his unique approach to workshop manual publishing has proved so successful that millions of Haynes Manuals are now sold every year throughout the world, covering literally thousands of different makes and models of cars, vans and motorcycles.

EDINBURGH CITY LIBRARIES .

A continuing passion-for cars and motoring led to the founding in 1985 of a Charitable Trust dedicated to the restoration and preservation of our motoring heritage. To inaugurate the new Museum, John Haynes donated virtually his entire private collection of 52 cars. Now with an unrivalled international collection of over 210 veteran,

vintage and classic cars and motorcycles, the Haynes Motor Museum in Somerset is well on the way to becoming one of the most interesting Motor Museums in the world.

A 70 seat video cinema, a cafe and an extensive motoring bookshop, together with a specially constructed one kilometre motor circuit, make a visit to the Haynes Motor Museum a truly unforgettable experience. Every vehicle in the museum is preserved in as near as possible mint condition and each car is run every six months on the motor circuit.

Acknowledgements Thanks are due to Champion Spark Plug, who supplied replacement component information, and to Duckhams Oils, who provided lubrication data. Certain illustrations are the copyright of Citroén Cars Limited, and are used with their permission. Thanks are also due to Sykes-Pickavant Limited, who provided some of the workshop tools, and to all those people at Sparkford who helped in the production of this manual.

Enjoy. the picnic area set amongst the rolling Somerset hills. Peer through the William Morris workshop windows at cars being restored, and browse through the extensive displays of fascinating motoring memorabilia.

From the 1903 Oldsmobile through such classics as an MG Midget to the mighty 'E' Type Jaguar, Lamborghini, Ferrari Berlinetta Boxer, and Graham Hill's Lola Cosworth, there is something for everyone, young

and old alike, at this Somerset Museum. © Haynes Publishing 1994 A book in the Haynes Owners Workshop Manual Series

Printed by J. H. Haynes & Co. Ltd., Sparkford, Nr. Yeovil, Somerset BA22 7JJ, England 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, without permission in writing from the copyright holder.

ISBN 1 85010 964 8 British Library Cataloguing in Publication Data A catalogue record for this book is available from the British Library.

We take great pride in the accuracy of information given in this manual, but vehicle manufacturers make alterations and design changes during the production run of a particular vehicle of which they do not inform us. 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.

Haynes Motor Museum Situated mid-way between London and Museum is located just off the A303 at the Haynes Manual) and is open to the round, except Christmas Day and Boxing

Penzance, the Haynes Motor Sparkford, Somerset (home of public 7 days a week all year Day.

Page

Acknowledgements

2

About this manual

5

Introduction to the Citroén 1.7 and 1.9 diesel engines

5

General dimensions, weights and capacities

6

Jacking (Visa Saloon models)

7

Buying spare parts

7

General repair procedures

8

Tools and working facilities

9

Conversion factors

|

11

Safety first!

12

Routine maintenance (also see Chapter 8 page 152)

13

Recommended lubricants and fluids

18

Fault diagnosis

19

Chapter 1 Engine (also see Chapter 8, page 152)

22

Chapter 2 Cooling system (also see Chapter 8 page 152)

78

Chapter 3 Fuel and exhaust systems (also see Chapter 8, page 152)

85

Chapter 4 Clutch, transmission and driveshafts (also see Chapter 8, page 152)

107

Chapter 5 Braking and hydraulic systems

115

Chapter 6 Suspension and steering

121

Chapter 7 Electrical system (also see Chapter 8 page 152)

125

Chapter 8 Supplement: Revisions and information on later models

152

Index

18 wo

Front three-quarter view of Citroén XUD engine. Timing belt cover has been removed Timing belt Oil filler cap and ventilation hose Injectors Diagnostic socket Temperature sensors Fast idle thermo unit Hm» AaAAR®

7 8

Thermostat cover Injection pump (Roto-Diesel) Coolant hose to oil cooler

2) 70 Drivebelt tension adjusting bolt

171 Flywheel

12 73 14 15 716 17

Alternator Oil filler Sump Alternator drivebelt Crankshaft pulley Water pump

18 Timing belt intermediate roller 19 Injection pump sprocket 20 Timing belt tensioner at Right-hand engine mounting bracket

22 Camshaft sprocket

|

About

this manual

[ts aim The aim of this manual is to help you get the best value vehicle. It can do so in several ways. It can help you decide must be done (even should you choose to get it done by provide information on routine maintenance and servicing,

logical course

of action and diagnosis when

random

from your what work a garage), and give a

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 and paragraph to which they relate.

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. 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.

Its arrangement The manual is divided into Chapters, each covering a logical subdivision of the vehicle. The Chapters are each divided into Sections, numbered with single figures, eg 5; the Sections are divided into paragraphs, or into sub-sections and paragraphs. 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

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.

by turning

Vehicle manufacturers continually make changes to specifications and recommendations, and these, when notified, are incorporated into Our manuals at the earliest opportunity.

We take great pride in the accuracy of information given in this manual, but vehicle manufacturers make alterations and design changes during the production run of a particular vehicle of which they do not inform us. 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.

Project vehicles 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 vehicle used in the preparation of the Supplement (Chapter 8) was a BX Turbo Diesel.

Introduction to

the Citroén 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 Citroén 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 one or 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: Wissen: SalOOn igahssissaosceeecetetecasee sassconeveilscarecadiacscene ortochetceooere rece mane C15/Champ Van BX. Saloon: ——a

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15

16

Fig. 7.3 Wiring diagram for Visa Diesel Vans to early 1993

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18

| 21

144

Fig. 7.3 Wiring diagram for Visa Diesel Vans to early 1993 (continued)

145

Fig. 7.3 Wiring diagram for Visa Diesel Vans to early 1993 (continued)

146

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17

18

Fig. 7.3 Wiring diagram for Visa Diesel Vans to early 1993 (continued)

«19

«20

147

Key to wiring diagrams for Visa models to early 1993 Cigar lighter Distributor Alternator Horn Battery Monitoring unit Ignition coil Ignition unit (module) Electronic unit for oil level Preheater control unit Sparking plugs Heater plugs TDC sensor Ignition pick up No 1 Ignition pick up No 2 Ignition vacuum sensor Speed sensor Computer Flasher unit

Tailgate Tailgate Contact Contact

switches on keyboard contact switch switch for door locking device switch for reversing lamps

Stop-lamp contact switch Handbrake contact switch Contact switch on throttle spindle

Choke contact switch Anti-theft device contact switch Door pillar contact switch (LH front door) Door pillar contact switch (RH front door) Contact switch for brake fluid level Contact switch for min water level Lighting switch Selector switch for window wiper, flasher, horn Selector switch for lighting, flasher, horn Switch for lighting, windscreen wiper, flasher, horn Selector switch for screen wipe/wash Auxiliary-air regulator Condenser coil ‘+’ terminal Tachometer Horn compressor Starter motor Flowmeter Electric cut-out control on pump Lighting for heater control Ashtray lighting

Boot lighting Lighting for LH number plate Lighting for. RH number plate Lighting for anti-theft switch Floor lighting, passenger side Idle cut-off LH sidelamp RH sidelamp LH tail lamp RH tail lamp LH rear lamp (cluster) RH rear lamp (cluster)

457 458 460 461 462 463 470 476 477 478 479 480 481 482 483 488 489 502 503 511 520 521 532 547 550 551 558 570 576 580 590 600 601 615 616 626 627 628 634 635 640 650 670 671 675 676 680 681 683 690 720 721 731 733 737 743 761 765

LH stop-lamp RH stop-lamp LH rear foglamp

RH rear foglamp LH reversing lamp RH reversing lamp Fuses reversing lamp LH dipped beams RH dipped beams LH main beams RH main beams

LH RH LH RH LH

front direction indicator front direction indicator rear direction indicator rear direction indicator main and dipped beams

RH main and dipped beams LH rear loudspeaker RH rear loudspeaker

Rear foglamp switch Switch for LH front window winder Switch for RH front window winder Switch for heated rear window Check button for brake fluid level warning lamp Switch for rear window wipe/wash Switch for rear screen intermittent wiper Switch for air cooling fan Switch for hazard warning signal Injectors Fuel gauge Map reading lamp Windscreen wiper motor Rear window wiper motor LH front window winder motor RH front window winder motor

Motor for RH front door locking device Motor for LH rear door locking device Motor for RH rear door locking device Engine electric cooling fan, RH Engine electric cooling fan, LH Clock Oil pressure switch LH headlamp RH headlamp LH front brake pads RH front brake pads Windscreen washer pump Rear screen washer pump Petrol pump Centre interior lamp Diagnostic socket Radio terminals Injection relay Electric fan relay Dipped beams relay Horn compressor relay Front window winder relay Windscreen wiper relay

148

Key to wiring diagrams for Visa models to early 1993 (continued) 766 770 ihe: 773 788 795 810 811 835

Rear screen wiper relay Relays for accesories Relay for electric fan 2nd speed Relay reversing the electric fan speeds Electric fan 2nd speed resistance Rheostat for illumination LH side repeater RH side repeater Probe for oil level

840 841

842 843

850 855

935 945 958

Water temperature sensor Water temperature sensor (injection) Oil pressure sensor Oil temperature sensor Electric fan thermal switch on coolant circuit Water temperature switch Air conditioning cooling fan Heated rear window Preheating warning lamp

Not all items fitted to all models

Harness code

A B Cc D E F G H J K L

Front (no mark on feed and function diagrams) Electric fan LH front door Diagnostic Boot lighting From LH rear lamp to RH rear lamp Rear screen washer time-delay Tailgate, RH Gauge Passenger’s door Window winder locking device

M N P R S 1E U V Ww Y Z

Engine Rear door Interior lamp, gauge Rear

Tailgate, LH Instrument panel Brake wear Rear window wiper Rear window wiper switch Injection Ignition

Colour code

White

Mv

Mauve

Blue Grey Transparent Yellow Brown

N Or

Black Orange

R V

Red Green

Key to wiring diagram for BX models No 1 2

Description Front direction indicator, RH side RH headlamp: sidelamp Main and dipped beams Water level switch Electric fan double thermal switch Electric cooling fan Electric fan resistor W NOOR LH headlamp: sidelamp Main and dipped beams 8 Connector for LH side repeater 9 LH front direction indicator 10 Connector for RH side repeater

Position

Description

Starter motor Horn Alternator with integrated regulator Hydraulic fluid level switch Stop electrovalve on injection pump Heater plugs Engine oil pressure switch Water temperature warning switch Water temperature switch (flasher) Reversing lamp switch Battery Stop electrovalve relay on Roto-Diesel pump

Position 2to 4 50 7 to 11 28

149 Key to wiring diagram for BX models (continued)

No

Description

23 24 25

Preheating box LH front brake unit (wear) RH front brake unit (wear)

26 27 28

Diagnostic socket TDC sensor (diagnostic) Plug for tachometer Rear window washer pump Engine oil level sensor Windscreen washer pump Hydraulic fluid pressure switch Windscreen wiper motor Connection box (see detail)

29 30 31 32 33 34 35 36 37 38 39 40

Position

No

4to6 30 31

Double channel “Boomer”

Position

Emergency stop warning lamp and “STOP” test-button 22, 25, 27, 30 Hydraulic fluid level warning lamp (pressure

9, 18 to 21 18, 19 9 61 23, 24 56 27 51 to 55

_ Description

and level) Engine oil pressure warning lamp Coolant level warning lamp

28 26 29 20 3, 6, 36, 55 78 74 89 92 to 99

54 55 56 57 58

Preheating warning lamp Anti-theft switch Lighting rheostat (via anti-theft switch) Stop-lamp switch (braking) LH loudspeaker LH control unit: lighting

82 86 65 to 67 107, 108 58, 59 35 83 103, 109 78 79, 80 36, 37 36 79

59 60 61 62 63 64 65 66 67 68 69 70 71

Electronic unit for engine oil level LH front door switch LH front window winder motor LH front door locking device unit LH interior lamp LH front door locking device switch RH interior lamp RH rear window winder motor RH rear door locking device motor RH rear door locking device switch RH rear door switch Handbrake switch Accessory plug

23 to 25 81 62 to 64 103, 104 81 32 83 71 to 73 107 34 81 39 79

87, 88

Direction indicators

40, 41

41 42 43 44 45 46 47 48

RH front door switch RH loudspeaker RH front window winder motor RH front door locking device unit Rear window wiper timer unit RH front door locking device switch Glove compartment lighting Electronic unit for door locking device Ashtray lighting Cigar lighter and lighting Air blower resistors Air blower Ashtray lighting

49

Air blower control and lighting

36, 37, 75 to 77

72

RH rear window winder switch

71 to 73

50

Radio connections

86 to 89

73

LH front window winder switch

62 to 64

51

RH control unit: horn Windscreen wiper and washer

50 53 to 56

74 75

RH front window winder switch LH rear window winder switch

65 to 68 68 to 70

46 to 48 42 to 45

76 77

16 to 17 81

20, 21 77,78 95 94 93 38 92 32 to 35 39 90 24, 25 ins 18, 20 11 16

78 79 80 81 82

Fuel gauge rheostat Map reading lamp LH rear window winder motor

Heated rear window Hazard warning device

52 53

Water temperature flasher Dashboard: lighting Main beam warning lamp Dipped beam warning lamp Sidelamp warning lamp Direction indicator warning lamp Rear foglamp warning lamp Door locking device warning lamp Handbrake warning lamp Clock Engine oil level indicator Fuel gauge indicator Tachometer Battery charge warning lamp Fuel min level warning lamp

Water temperature warning lamp Front brake wear warning lamp

LH rear door LH rear door LH rear door RH rear lamp Stop-lamp,

locking device motor switch locking device switch cluster: tail lamp Foglamp

Reversing lamp, Direction indicator

83

Number plate lighting, RH

84 85

Heated rear window Tailgate locking device motor

86 87 88 89

Rear window wiper motor Number plate lighting, LH Boot lighting switch Boot lighting

90

LH rear lamp cluster: tail lamp

22

Stop-lamp, Fog lamp

31

Reversing lamp, Direction indicator

68, 70 104 82 33 97 75, 92 13, 44 95 49 105 57 to 59 94 85 85 96

74, 91 12, 43

Earthing points m1 m2 m3 m4 m5

Earthing Earthing Earthing Earthing Earthing

point point point point point

for for for for an

RH front brake pad wear battery on bodyshell LH front brake pad wear connection box and dashboard console

m6 m7 ms

Earthing RH rear LH rear and RH

point on windscreen frame upper part earthing point (rear window wiper) earthing point (heated rear window, boot LH rear lamps)

Harness code

Front Heater unit Diagnostic Windscreen wiper and dashboard Flat, rear lamp interconnection Tailgate, LH Passenger compartment Fuel gauge Zzcrammoop Engine

Engine pre-heating Interior lamp

Flat, rear Radio Roto-Diesel Front brake Tailgate, RH S