Manual ZX

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2C*1
Chapter 2 Part C:
Engine removal and general overhaul procedures
Contents
Crankshaft - inspection 14
Engine overhaul - dismantling sequence 6
Crankshaft - refitting and main bearing running clearance check . . 1 8
Engine overhaul - general information 2
Crankshaft - removal 11
Engine overhaul - reassembly sequence 16
Cylinder block/crankcase - cleaning and inspection 12
Engine/transmission removal - methods and precautions 3
Cylinder head - dismantling 7
General information 1
Cylinder head - reassembly 9
Main and big-end bearings - inspection 15
Cylinder head and valves - cleaning and inspection 8
Piston/connecting rod assembly - inspection 13
Engine - initial start-up after overhaul 20
Piston/connecting rod assembly - refitting and big-end bearing
Engine and automatic transmission - removal, separation and
running clearance check 19
refitting 5
Piston/connecting rod assembly - removal 10
Engine and manual transmission - removal, separation and
Piston rings - refitting 17
refitting 4
Degrees of difficulty
Easy, suitable for
Fairly easy, suitable
Fairy difficult, suitable
Difficult, suitable for
Very difficult,
novice with little
for beginner with
for competent DIY
experienced DIY
suitable for expert DIY
experience
some experience
mechanic
mechanic
or professional
Specifications
Note:
At the time of writing, many specifications for the 1761 cc and 1998 cc engines were not available. Where the relevant specifications are not
given here, refer to your Citroen dealer for further information.

Cylinder head
Maximum gasket face distortion 0.05 mm
Cylinder head height:
Standard:
1124 cc and 1360 cc engines 111.2 0.08 mm
1580 cc, 1761 cc, 1905 cc and 1998 cc 8-valve engines 141.0 0.05 mm
1998 cc 16-valve engine 132.0 0.15 mm
Minimum after refinishing:
1124 cc and 1360 cc engines 111.0 mm
1580 cc, 1761 cc, 1905 cc and 1998 cc 8-valve engines 140.8 mm
1998 cc 16-valve engine 131.85 mm
Pistons
Piston diameter:
1124 cc engine:
SizegroupA 71.940 0.010 mm
Size group B 71.950 0.010 mm
Size group C 71.960 0.010 mm
1360 cc engine:
Size group A 74.950 0.010 mm
Size group B 74.960 0.010 mm
Size group C 74.970 0.010 mm
1580 cc, 1761 cc and 1905 cc engines:
Size group A 82.960 0.007 mm
Size group B 82.970 0.007 mm
Size group C 82.980 0.007 mm
1998 cc engines Not available

2C*2 Engine removal and general overhaul procedures
Cylinder block
Cylinder bore diameter:
1124 cc engine:
Size group A 72.000 to 72.010 mm
Size group B 72.010 to 72.020 mm
Size group C 72.020 to 72.030 mm
1360 cc engine:
Size group A 75.000 to 75.010 mm
Size group B 75.010 to 75.020 mm
Size group C 75.020 to 75.030 mm
1580 cc, 1761 cc and 1905 cc engines:
Size group A 83.000 to 83.010 mm
Size group B 83.010 to 83.020 mm
Size group C 83.020 to 83.030 mm
1998 cc engines Not available (86 mm nominal)
Liner protrusion above block mating surface - aluminium-block engine (ie all except 1998 cc) only:
Standard 0.03 to 0.10 mm
Maximum difference between any two liners 0.05 mm
Crankshaft
Endfloat 0.07 to 0.32 mm
Main bearing journal diameter:
1124 cc and 1360 cc engines:
Standard 49.965 to 49.981 mm
Undersize 49.665 to 49.681 mm
1580 cc and 1905 cc engines:
Standard 59.981 to 60.000 mm
Undersize 59.681 to 59.700 mm
1761 cc and 1998 cc engines Not available
Big-end bearing journal diameter:
1124 cc and 1360 cc engines:
Standard 44.975 to 45.000 mm
Undersize 44.675 to 44.700 mm
1580 cc and 1905 cc engines:
Standard 49.984 to 50.000 mm
Undersize 49.684 to 49.700 mm
1761 cc and 1998 cc engines Not available
Maximum bearing journal out-of-round (all models) 0.007 mm
Main bearing running clearance:
1124 cc and 1360 cc models*:
Pre-February 1992 models 0.023 to 0.083 mm
February 1992-on models 0.023 to 0.048 mm
1580 cc, 1761 ccand
1905 cc engines** 0.025 to 0.050 mm
1998 cc engines 0.038 to 0.069 mm
Big-end bearing running clearance - all models** 0.025 to 0.050 mm
*On 1124 ccand 1360 cc models, the main bearing shells were modified in February 1992, resulting in a reduction in the specified running
clearance - see text for further information.
**These are suggested figures, typical for this type of engine
- no exact values are stated by Citroen.
Piston rings
End gaps:
Top compression ring:
1124 cc engine 0.25 to 0.45 mm
1360 cc engine 0.3 to 0.5 mm
1580 cc engine 0.4 to 0.6 mm
1905 cc engine 0.2 to 0.4 mm
1761 cc and 1998 cc engines* 0.3 to 0.5 mm
Second compression ring:
1124 cc engine 0.25 to 0.45 mm
1360 cc engine 0.3 to 0.5 mm
1580 cc and 1905 cc engines 0.15 to 0.35 mm
1761 cc and 1998 cc engines* 0.3 to 0.5 mm
Oil control ring:
1124 cc engine 0.20 to 0.45 mm
All other models* 0.3 to 0.5 mm
*These are suggested figures, typical for this type of engine - no exact values are stated by Citroen.

Engine removal and general overhaul procedures 2C*3
Connecting rods
Maximum weight difference between any two piston/connecting rod assemblies:
1124 cc and 1360 cc engines 5.0 g
1580 cc, 1761 cc and 1905 cc engines 13.0 g
1998 cc engines 7.0 g
Valves
Valve head diameter:
Inlet:
1124 cc and 1360 cc engines 36.8 mm
1580 cc engine 41.6 mm
1761 cc engine Not available
1905 cc engine 41.8 mm
1998 cc 8-valve engine 42.6 mm
1998 cc 16-valve engine 34.7 mm
Exhaust:
1124 cc and 1360 cc engines : ,, 29.4 mm
1580 cc and 1905 cc engines 34.7 mm
1761 cc engine Not available
1998 cc 8-valve engine 34.5 mm
1998 cc 16-valve engine 29.7 mm
Valve stem diameter:
Inlet:
1124 cc and 1360 cc engines 6.84 to 6.99 mm
1580 cc and 1905 cc engines 7.83 to 7.98 mm
1761 cc and 1998 cc engines Not available
Exhaust:
1124 cc and 1360 cc engines 6.83 to 6.98 mm
1580 cc and 1905 cc engines 7.83 to 7.98 mm
1761 cc and 1998 cc engines Not available
Overall length:
Inlet:
1124 cc and 1360 cc engines 112.76 0.25 mm
1580 cc and 1905 cc engines 108.79 0.1 mm
1761 cc and 1998 cc engines Not available
Exhaust:
1124 cc and 1360 cc engines 112.56 0.25 mm
1580 cc and 1905 cc engines 108.37 0.1 mm
1761 cc and 1998 cc engines Not available
Torque wrench settings
TU series engine - 1124 cc and 1360 cc
Refer to Chapter 2 Part A Specifications
XU series engine - 1580 cc and larger
Refer to Chapter 2 Part B Specifications
components necessary for full overhaul, refer
High mileage is not necessarily an
indication that an overhaul is needed, while
1 General information
to Part A or B of this Chapter (as applicable)
and to Section 6. Ignore any preliminary
low mileage does not preclude the need for an
dismantling operations described in Part A
overhaul. Frequency of servicing is probably
(1124 cc and 1360 cc models) or Part B (1580
the most important consideration. An engine
Included in this Part of Chapter 2 are details
cc and larger models) that are no longer
which has had regular and frequent oil and
of removing the engine/transmission from the
relevant once the engine has been removed
filter changes, as well as other required
car and general overhaul procedures for the
from the car.
maintenance, should give many thousands of
cylinder head, cylinder block/crankcase and
miles of reliable service. Conversely, a
Apart from torque wrench settings, which
all other engine internal components.
neglected engine may require an overhaul
are given at the beginning of Part A or Part B,
The information given ranges from advice
very early in its life.
all specifications relating to engine overhaul
concerning preparation for an overhaul and
are at the beginning of this Part of Chapter 2.
Excessive oil consumption is an indication
the purchase of replacement parts, to detailed
that piston rings, valve seals and/or valve
step-by-step procedures covering removal,
guides are in need of attention. Make sure
inspection, renovation and refitting of engine
2 Engine overhaul -
that oil leaks are not responsible before
internal components.
general information
deciding that the rings and/or guides are
After Section 6, all instructions are based
worn. Perform a compression test, as
on the assumption that the engine has been
It is not always easy to determine when, or
described in Part A of this Chapter, to
removed from the car. For information
if, an engine should be completely
determine the likely cause of the problem.
concerning in-car engine repair, as well as the
overhauled, as a number of factors must be
Check the oil pressure with a gauge fitted in
removal and refitting of those external
considered.
place of the oil pressure switch, and compare

2C*4 Engine removal and general overhaul procedures
it with that specified. If it is extremely low, the
is the primary cost of an overhaul, so it does
make sure that you arrange for it in advance,
main and big-end bearings, and/or the oil
not pay to fit worn or sub-standard parts.
and perform all of the operations possible
pump, are probably worn out.
As a final note, to ensure maximum life and
without it beforehand. This will save you
Loss of power, rough running, knocking or
minimum trouble from a reconditioned engine,
money and time.
metallic engine noises, excessive valve gear
everything must be assembled with care, in a
7 Plan for the car to be out of use for quite a
noise, and high fuel consumption may also
spotlessly-clean environment.
while. An engineering works will be required
point to the need for an overhaul, especially if
to perform some of the work which the do-it-
they are all present at the same time. If a
yourselfer cannot accomplish without special
complete service does not remedy the
equipment. These places often have a busy
3 Engine/transmission removal -
situation, major mechanical work is the only
schedule, so it would be a good idea to
methods and precautions
solution.
consult them before removing the engine, in
An engine overhaul involves restoring all
order to accurately estimate the amount of
1 If you have decided that the engine must be
internal parts to the specification of a new
time required to rebuild or repair components
removed for overhaul or major repair work,
engine. During an overhaul, the cylinder liners
that may need work.
several preliminary steps should be taken.
(where applicable), the pistons and the piston
8 Always be extremely careful when removing
2 Locating a suitable place to work is
rings are renewed. New main and big-end
and refitting the engine/transmission. Serious
extremely important. Adequate work space,
bearings are generally fitted; if necessary, the
injury can result from careless actions. Plan
along with storage space for the car, will be
crankshaft may be renewed, to restore the
ahead and take your time, and a job of this
needed. If a workshop or garage is not
journals. The valves are also serviced as well,
nature, although major, can be accomplished
available, at the very least, a flat, level, clean
since they are usually in less-than-perfect
successfully.
work surface is required.
condition at this point. While the engine is
being overhauled, other components, such as
3 Cleaning the engine compartment and
the distributor, starter and alternator, can be
engine/transmission before beginning the
4 Engine and manual
overhauled as well. The end result should be
removal procedure will help keep tools clean
an as-new engine that will give many trouble-
and organized.
transmission - removal,
free miles.
4 An engine hoist or A-frame will also be
separation and refitting
necessary. Make sure the equipment is rated
Note: Critical cooling system components
in excess of the combined weight of the
such as the hoses, thermostat and water
engine and transmission. Safety is of primary
Removal
pump should be renewed when an engine is
importance, considering the potential hazards
overhauled. The radiator should be checked
Note: The engine can be removed from the
involved in lifting the engine/transmission out
carefully, to ensure that it is not clogged or
car only as a complete unit with the
of the car.
leaking. Also, it is a good idea to renew the oil
transmission; the two are then separated for
5 If this is the first time you have removed an
pump whenever the engine is overhauled.
overhaul.
engine, an assistant should ideally be
Before beginning the engine overhaul, read
1 Park the vehicle on firm, level ground.
available. Advice and aid from someone more
through the entire procedure, to familiarise
Chock the rear wheels, then firmly apply the
experienced would also be helpful. There are
yourself with the scope and requirements of
handbrake. Jack up the front of the vehicle,
many instances when one person cannot
the job. Overhauling an engine is not difficult if
and securely support it on axle stands.
simultaneously perform all of the operations
you follow carefully all of the instructions,
Remove both front roadwheels.
required when lifting the engine out of the
have the necessary tools and equipment, and
2 Set the bonnet in the upright position, and
vehicle.
pay close attention to all specifications. It can,
remove the battery and battery tray as
6 Plan the operation ahead of time. Before
however, be time-consuming. Plan on the car
described in Chapter 5. Slacken and remove
starting work, arrange for the hire of or obtain
being off the road for a minimum of two
the battery support plate retaining bolts. Free
all of the tools and equipment you will need.
weeks, especially if parts must be taken to an
the wiring from its retaining clips on the edge
Some of the equipment necessary to perform
engineering works for repair or reconditioning.
of the plate, and remove the plate.
engine/transmission removal and installation
Check on the availability of parts and make
3 Remove the complete air cleaner housing
safely and with relative ease (in addition to an
sure that any necessary special tools and
and duct assembly, as described in the
engine hoist) is as follows: a heavy duty trolley
equipment are obtained in advance. Most
relevant Part of Chapter 4 (see illustrations).
jack, complete sets of spanners and sockets
work can be done with typical hand tools,
4 If the engine is to be dismantled, working as
as described in the front of this manual,
although a number of precision measuring
described in Chapter 1, first drain the oil and
wooden blocks, and plenty of rags and
tools are required for inspecting parts to
remove the oil filter. Clean and refit the drain
cleaning solvent for mopping up spilled oil,
determine if they must be renewed. Often the
plug, tightening it securely.
coolant and fuel. If the hoist must be hired,
engineering works will handle the inspection
5 Drain the transmission oil as described in
of parts and offer advice concerning
reconditioning and renewal.
Note: Always wait until the engine has been
completely dismantled, and until all
components (especially the cylinder
block/crankcase and the crankshaft) have

been inspected, before deciding what service
and repair operations must be performed by

an engineering works. The condition of these
components will be the major factor to
consider when determining whether to
overhaul the original engine, or to buy a
reconditioned unit. Do not, therefore,

purchase parts or have overhaul work done on
other components until they have been

4.3a Remove the air cleaner housing . . .
4.3b . . . and intake duct -1360 cc model
thoroughly inspected. As a general rule, time
shown

Engine removal and general overhaul procedures 2C*5
Chapter 1. Refit the drain and filler plugs, and
(d) Disconnect the wiring connector(s) from
over the front of the body, and lower the unit
tighten them to their specified torque settings.
the reversing light switch and
to the ground.
6 Remove the alternator as described in
speedometer drive (as applicable).
1580 cc models
Chapter 5.
15 Remove the right-hand driveshaft as
7 Where applicable, remove the power
described in Chapter 8.
26 Carry out the following operations, using
steering pump as described in Chapter 10.
16 Free the left-hand driveshaft inner end
the information given in Chapter 4:
8 On models with air conditioning, unbolt the
from the transmission, as described in
(a) Depressurise the fuel system. Disconnect
compressor, and position it clear of the
Chapter 7, Part A, Section 4.
the fuel feed and return hoses from the
engine unit. Support the weight of the
17 Disconnect the wiring connectors from
throttle body, and free the hoses from any
compressor by tying it to the vehicle body, to
the components listed below. To aid refitting,
relevant retaining clips.
prevent any excess strain being placed on the
label each connector as it is disconnected.
(b) Disconnect the accelerator cable from the
compressor lines whilst the engine is
This will prevent connectors being wrongly
throttle body.
removed. Do not disconnect the refrigerant
connected on refitting, and will also prove
(c) Disconnect the wiring connectors from
lines from the compressor (refer to the
helpful when re-routing the loom around the
the throttle body and intake air
warnings given in Chapter 3).
engine compartment.
temperature sensor.
(d) Disconnect the purge valve and braking
9 Drain the cooling system (see Chapter 1),
(a) Oil pressure switch on cylinder block front
system servo vacuum hoses from the inlet
saving the coolant if it is fit for re-use.
face.
manifold.
Although not essential, it may also be worth
(b) Coolant temperature switch/senders
(e) Disconnect the exhaust system front pipe
removing the radiator (Chapter 3), which is
screwed into the thermostat housing/left-
from the manifold.
easily damaged during engine removal.
hand end of cylinder head.
(c) Distributor (where fitted) or ignition HT
(f) Remove the auxiliary air valve (where
1124 cc and 1360 cc models
coil.
fitted).
10 On carburettor models, carry out the
(d) TDC sensor.
27 Slacken the retaining clips, then
following operations, using the information
disconnect the radiator top hose from the
(e) Starter motor (see Chapter 5).
given in Chapter 4:
thermostat housing, and the radiator bottom
18 Check that all necessary wiring
(a) Disconnect the fuel feed hose from the
hose from the water pump housing. Trace
connectors have been disconnected from the
anti-percolation chamber.
both coolant hoses back from the heater
engine, then free the wiring loom from its
(b) Disconnect the accelerator and choke
matrix union on the engine compartment
retaining clips. Free the loom from the engine,
cables from the carburettor.
bulkhead, and disconnect them from the
noting its correct routing, and position it so
engine. Also trace the small-bore coolant
(c) Disconnect the braking system servo
that it will not hinder the engine/transmission
hose back from the right-hand side of the
vacuum hose from the inlet manifold.
lifting procedure.
radiator to the engine, and disconnect these
(d) Remove the exhaust system front pipe.
19 Manoeuvre the engine hoist into position,
from the engine. Position all hoses clear of the
11 On fuel injection models, carry out the
and attach it to the lifting brackets bolted onto
engine, so that they do not hinder the removal
following operations, using the information
the cylinder head. Raise the hoist until it is
procedure.
given in Chapter 4:
supporting the weight of the engine.
(a) Depressurise the fuel system, and
28 Working as described in Chapter 6,
20 Slacken and remove the centre nut and
disconnect the fuel feed and return hoses
disconnect the clutch cable from the
washer from the engine/transmission left-
from the throttle body.
transmission, and position it clear of the
hand mounting. Undo the two bolts securing
working area.
(b) Disconnect the accelerator cable from the
the mounting bracket assembly to the vehicle
throttle body.
body, and remove the mounting bracket
29 Carry out the following operations, using
the information given in Chapter 7:
(c) Disconnect the wiring connectors from
assembly.
the throttle body.
(a) Disconnect the gearchange mechanism
21 From underneath the vehicle, slacken and
link rods from the transmission.
(d) Disconnect the purge valve and/or
remove the nuts and bolts securing the rear
braking system servo vacuum hoses from
(b) Disconnect the speedometer cable from
mounting bracket to the mounting assembly
the inlet manifold (as applicable).
the speedometer drive.
and subframe, and remove the bracket.
(c) Release the power steering pipe from the
(e) Remove the exhaust system front pipe.
22 Undo the three nuts securing the
underside of the transmission.
12 Slacken the retaining clips, then
engine/transmission right-hand mounting
(d) Disconnect the wiring connector(s) from
disconnect the radiator top hose from the
bracket to the engine. Remove the single nut
the reversing light switch and
thermostat housing, and the radiator bottom
securing the bracket to its mounting rubber,
speedometer drive (as applicable).
hose from the water pump housing. Trace
and remove the bracket (see illustration).
both coolant hoses back from the heater
30 Remove the right-hand driveshaft as
23 Make a final check that any components
matrix union on the engine compartment
described in Chapter 8.
which would prevent the removal of the
bulkhead, and disconnect them from the
engine/transmission from the car have been
engine. Position all hoses clear of the engine,
removed or disconnected. Ensure that
so that they do not hinder the removal
components such as the gearchange selector
procedure.
rod are secured so that they cannot be
13 Working as described in Chapter 6,
damaged on removal.
disconnect the clutch cable from the
24 Lift the engine/transmission out of the car,
transmission, and position it clear of the
ensuring that nothing is trapped or damaged.
working area.
Enlist the help of an assistant during this
14 Carry out the following operations, using
procedure, as it will be necessary to tilt the
the information given in Chapter 7:
assembly slightly to clear the body panels.
(a) Disconnect the gearchange selector rod
Great care must also be taken to ensure that
from the transmission.
the radiator (if not removed) and, on right-
(b) Disconnect the speedometer cable from
hand drive models, the braking system master
the speedometer drive.
cylinder reservoir, are not damaged during the
(c) Release the power steering pipe from the
removal procedure.
4.22 Engine/transmission right-hand
underside of the transmission.
25 Once the engine is high enough, lift it out
bracket retaining nuts (arrowed)

2C*6 Engine removal and general overhaul procedures
(d) Disconnect the purge valve and/or
braking system servo vacuum hoses from
the inlet manifold (as applicable).

(e) Disconnect the exhaust system front pipe
from the manifold.
(f) On models with a catalytic converter,
remove the airflow meter.
38 The engine and transmission can then
be removed as described above in para-
graphs 27 to 34.
1998 cc 8-valve models
39 Carry out the following operations, using
4.35a On 1761 cc models, disconnect the
the information given in Chapter 4:
4.35b . . . and remove the auxiliary air
wiring connectors (arrowed) from the
(a) Depressurise the fuel system. Disconnect
valve
throttle housing . . .
the fuel feed and return hoses from the
fuel rail, and free the hoses from any
31 Free the left-hand driveshaft inner end
(a) Depressurise the fuel system. Disconnect
relevant retaining clips.
from the transmission, as described in
the fuel feed and return hoses from the
(b) Disconnect the accelerator cable from the
Chapter 7, Part A, Section 4.
fuel rail, and free the hoses from any
throttle housing.
32 Disconnect the wiring connectors from
relevant retaining clips.
(c) Disconnect the wiring connectors from
the components listed below. To aid refitting,
(b) Disconnect the accelerator cable from the
the throttle housing, knock sensor, and
label each connector as it is disconnected.
throttle housing.
the fuel injectors.
This will prevent connectors being wrongly
(c) Disconnect the wiring connectors from
(d) Disconnect the purge valve and braking
connected on refitting, and will also prove
the throttle housing and fuel injectors (see
system servo vacuum hoses from the inlet
helpful when re-routing the loom around the
illustration).
manifold.
engine compartment.
(d) Disconnect the purge valve and braking
(e) Disconnect the exhaust system front pipe
(a) Oil pressure switch, oil level sender
system servo vacuum hoses from the inlet
from the manifold.
and/or oil temperature switch (as
manifold.
(f) Remove the ECU and its protective
applicable - see Chapter 5).
(e) Disconnect the exhaust system front pipe
plastic box.
(b) Coolant temperature switch/senders
from the manifold.
40 The engine and transmission can then
screwed into the thermostat housing/left-
(f) Remove the auxiliary air valve (see
be removed as described above in para-
hand end of cylinder head.
illustration).
graphs 27 to 34; note, however, that the engine
(c) Ignition HT coil.
(g) Remove the ECU and its protective
right-hand mounting is dismantled as follows.
(d) TDC sensor.
plastic box.
41 Undo the two bolts securing the curved
(e) Starter motor (see Chapter 5).
36 The engine and transmission can then
mounting retaining plate to the body. Lift off
33 Check that all necessary wiring
be removed as described above in para-
the plate, and withdraw the rubber damper
connectors have been disconnected from the
graphs 27 to 34.
from the top of the mounting bracket. Slacken
engine, then free the wiring loom from all its
and remove the two nuts and two bolts
relevant retaining clips. Free the loom from
1905 cc models
securing the right-hand mounting bracket to
the engine, noting its correct routing, and
37 Carry out the following operations, using
the engine. Remove the single nut securing
position it so that it will not hinder the
the information given in Chapter 4:
the bracket to the mounting rubber, and lift off
engine/transmission lifting procedure.
(a) Depressurise the fuel system. Disconnect
the bracket (see illustrations).
34 The engine and transmission can then
the fuel feed and return hoses from the
be removed as described above in para-
fuel rail, and free the hoses from any
1998 cc 16-valve models
graphs 19 to 25.
relevant retaining clips.
42 Carry out the following operations, using
1761 cc models
(b) Disconnect the accelerator cable from the
the information given in Chapter 4:
throttle housing.
(a) Depressurise the fuel system. Disconnect
35 Carry out the following operations, using
(c) Disconnect the wiring connectors from the
the fuel feed and return hoses from their
the information given in Chapter 4:
throttle potentiometer and fuel injectors.
fuel rail unions, and free the hoses from
the retaining clips on the cylinder head
cover.

(b) Remove the inlet manifold.
(c) Disconnect the wiring connectors from
the camshaft position sensor, knock
sensor, and the fuel injectors.
(d) Disconnect the exhaust system front pipe
from the manifold.
(e) Remove the ECU and its protective
plastic box.
43 Locate the ignition HT coil wiring
connector (on the left-hand end of the cylinder
head). Rotate the locking ring anti-clockwise,
and disconnect the connector from the main
4.41a Right-hand mounting curved
wiring loom.
4.41b . . . mounting bracket retaining
retaining plate retaining bolts (1), rubber
nuts (3) and bolts (4) - 1998 cc models
44 Disconnect the braking system servo
damper ( 2 ) . . .
vacuum hose from its union just to the rear of
the vacuum pump.

Engine removal and general overhaul procedures 2C*7
45 The engine and transmission can then
below in paragraphs 56 to 64. If not, proceed
bolts (as applicable) to their specified torque
be removed as described above in para-
as described from paragraph 65 onwards.
setting.
graphs 27 to 34; note, however, that the
56 Apply a smear of high-melting-point
69 On 1998 cc 8-valve and 16-valve models,
engine right-hand mounting is dismantled as
grease to the splines of the transmission input
refit the rubber damper to the top of the right-
follows.
shaft. Do not apply too much, otherwise there
hand mounting bracket. Refit the curved
46 Undo the two bolts securing the curved
is a possibility of the grease contaminating the
retaining plate, and tighten its retaining bolts
mounting retaining plate to the body. Lift off the
clutch friction plate.
to the specified torque.
plate, and withdraw the rubber damper from
57 Ensure that the locating dowels are
70 On all models, from underneath the
the top of the mounting bracket. Slacken and
correctly positioned in the engine or
vehicle, refit the rear mounting bracket, and
remove the two nuts and two bolts securing
transmission.
tighten both its retaining bolts to the specified
the right-hand mounting bracket to the engine.
58 On models with a "pull-type" clutch,
torque. The hoist can then be detached from
Remove the single nut securing the bracket to
position the clutch release bearing so that its
the engine and removed.
the mounting rubber, and lift off the bracket.
"HAUT" mark is at the top, and the "BAS"
71 The remainder of the refitting procedure is
mark is at the bottom. Align the release fork
a direct reversal of the removal sequence,
Separation
shaft mark with the second mark made on the
noting the following points:
47 With the engine/transmission assembly
transmission housing. This will ensure that the
(a) Ensure that the wiring loom is correctly
removed, support the assembly on suitable
release fork and bearing will engage correctly
routed and retained by all the relevant
blocks of wood, on a workbench (or failing
as the transmission is refitted to the engine.
retaining clips; all connectors should be
that, on a clean area of the workshop floor).
59 Carefully offer the transmission to the
correctly and securely reconnected.
48 Undo the retaining bolts, and remove the
engine, until the locating dowels are engaged.
(b) Prior to refitting the driveshafts to the
flywheel lower cover plate (where fitted) from
Ensure that the weight of the transmission is
transmission, renew the driveshaft oil
the transmission.
not allowed to hang on the input shaft as it is
seals as described in Chapter 7.
49 On models with a "pull-type" clutch
engaged with the clutch friction disc.
(c) Ensure that all coolant hoses are correctly
release mechanism (see Chapter 6 for further
60 On models with a "pull-type" clutch, with
reconnected, and securely retained by
information), tap out the retaining pin or
the transmission fully engaged with the
their retaining clips.
unscrew the retaining bolt (as applicable), and
engine, check that the release fork and
(d) Adjust the clutch cable as described in
remove the clutch release lever from the top
bearing are correctly engaged. If the release
Chapter 6.
of the release fork shaft. This is necessary to
fork and bearing are correctly engaged, the
(e) Adjust the choke cable and/or accelerator
allow the fork shaft to rotate freely, so that it
mark on the release fork should be aligned
cable (as applicable) as described in
disengages from the release bearing as the
with the original mark made on the
Chapter 4.
transmission is pulled away from the engine.
transmission housing (see Chapter 7, Part A,
(f) Refill the engine and transmission with
Make an alignment mark across the centre of
Section 7 for further information).
correct quantity and type of lubricant, as
the clutch release fork shaft, using a scriber,
61 Refit the transmission housing-to-engine
described in Chapter 1.
paint or similar, and mark its relative position
bolts, ensuring that all the necessary brackets
(g) Refill the cooling system as described in
on the transmission housing (see Chapter 7,
are correctly positioned, and tighten them to
Chapter 1.
Part A, Section 7 for further information).
the specified torque setting.
50 Slacken and remove the retaining bolts,
62 Refit the starter motor, and securely
and remove the starter motor from the
tighten its retaining bolts.
5 Engine and automatic
transmission.
63 On models with a "pull-type" clutch
transmission - removal,
51 Ensure that both engine and transmission
release mechanism, refit the clutch release
separation and refitting
are adequately supported, then slacken and
lever to the top of the release fork shaft,
remove the remaining bolts securing the
securing it in position with its retaining pin or
transmission housing to the engine. Note the
bolt (as applicable).
Removal
correct fitted positions of each bolt (and the
64 Where necessary, refit the lower flywheel
Note: The engine can be removed from the
relevant brackets) as they are removed, to use
cover plate to the transmission, and securely
car only as a complete unit with the
as a reference on refitting.
tighten its retaining bolts.
transmission; the two are then separated for
52 Carefully withdraw the transmission from
65 Reconnect the hoist and lifting tackle to
overhaul.
the engine, ensuring that the weight of the
the engine lifting brackets. With the aid of an
1 Carry out the operations described in
transmission is not allowed to hang on the
assistant, lift the assembly over the engine
paragraphs 1 to 9 of Section 4.
input shaft while it is engaged with the clutch
compartment.
1580 cc models
friction disc.
66 The assembly should be tilted as
53 If they are loose, remove the locating
necessary to clear the surrounding
2 Carry out the following operations, using
dowels from the engine or transmission, and
components, as during removal; lower the
the information given in Chapter 4:
keep them in a safe place.
assembly into position in the engine
(a) Depressurise the fuel system. Disconnect
54 On models with a "pull-type" clutch, make
compartment, manipulating the hoist and
the fuel feed and return hoses from the
a second alignment mark on the transmission
lifting tackle as necessary.
throttle body, and free the hoses from any
housing, marking the relative position of the
67 With the engine/transmission in position,
relevant retaining clips.
release fork mark after removal. This should
refit the right-hand engine/transmission
(b) Disconnect the accelerator cable from the
indicate the angle at which the release fork is
mounting bracket, tightening its retaining nuts
throttle body.
positioned. The mark can then be used to
and bolts (as applicable) by hand only at this
(c) Disconnect the wiring connectors from
position the release fork prior to installation, to
stage.
the throttle body and intake air
ensure that the fork correctly engages with
68 Refit the left-hand engine/transmission
temperature sensor.
the clutch release bearing as the transmission
mounting bracket assembly to the vehicle,
(d) Disconnect the purge valve and braking
is installed.
and tighten its retaining bolts to the specified
system servo vacuum hoses from the inlet
torque. Refit the centre nut and washer to the
manifold.
Refitting
left-hand mounting, tightening it to the
(e) Disconnect the exhaust system front pipe
55 If the engine and transmission have been
specified torque setting. Tighten the right-
from the manifold.
separated, perform the operations described
hand mounting bracket retaining nuts and
(f) Remove the auxiliary air valve (where fitted).

2C*8 Engine removal and general overhaul procedures
1761 cc models
8 Free the left-hand driveshaft inner end from
blocks of wood, on a workbench (or failing
that, on a clean area of the workshop floor).
3 Carry out the following operations, using
the transmission, as described in Chapter 7,
the information given in Chapter 4:
Part A, Section 4.
19 Detach the kickdown cable from the
9 Disconnect the wiring connectors from the
throttle cam. Work back along the cable,
(a) Depressurise the fuel system. Disconnect
components listed below. To aid refitting,
freeing it from any retaining clips, and noting
the fuel feed and return hoses from the
label each connector as it is disconnected.
its correct routing.
fuel rail, and free the hoses from any
This will prevent connectors being wrongly
relevant retaining clips.
20 Undo the retaining bolts and remove the
connected on refitting, and will also prove
driveplate lower cover plate from the
(b) Disconnect the accelerator cable from the
helpful when re-routing the loom around the
transmission, to gain access to the torque
throttle housing.
engine compartment.
converter retaining bolts. Slacken and remove
(c). Disconnect the wiring connectors from
(a) Oil pressure switch, oil level sender
the visible bolt. Rotate the crankshaft using a
the throttle housing and fuel injectors.
and/or oil temperature switch (as .
socket and extension bar on the pulley bolt,
(d) Disconnect the purge valve and braking
applicable - see Chapter 5).
and undo the remaining bolts securing the
system servo vacuum hoses from the inlet
(b) Coolant temperature switch/senders
torque converter to the driveplate as they
manifold.
screwed into the thermostat housing/left-
become accessible. There are three bolts in
(e) Disconnect the exhaust system front pipe
hand end of cylinder head.
total.
from the manifold.
(c) Ignition HT coil.
21 Slacken and remove the retaining bolts,
(f) Remove the auxiliary air valve.
(d) TDC sensor.
and remove the starter motor from the
(g) Remove the ECU and its protective
(e) Starter motor (see Chapter 5).
transmission.
plastic box.
10 Check that all necessary wiring
22 To ensure that the torque converter does
1905 cc models
connectors have been disconnected from the
not fall out as the transmission is removed,
4 Carry out the following operations, using
engine, then free the wiring loom from its
secure it in position using a length of metal
the information given in Chapter 4:
retaining clips. Free the loom from the engine,
strip bolted to one of the starter motor bolt
(a) Depressurise the fuel system. Disconnect
noting its correct routing, and position it so
holes.
the fuel feed and return hoses from the
that it will not hinder the engine/transmission
23 Ensure that both the engine and
fuel rail, and free the hoses from any
lifting procedure.
transmission are adequately supported, then
relevant retaining clips.
11 Manoeuvre the engine hoist into position,
slacken and remove the remaining bolts
(b) Disconnect the accelerator cable from the
and attach it to the lifting brackets bolted onto
securing the transmission housing to the
throttle housing.
the cylinder head. Raise the hoist until it is
engine. Note the correct fitted positions of
(c) Disconnect the wiring connectors from
supporting the weight of the engine.
each bolt (and any relevant brackets) as they
the throttle potentiometer and fuel
12 Slacken and remove the centre nut and
are removed, to use as a reference on
injectors.
washer from the engine/transmission left-
refitting.
(d) Disconnect the purge valve and/or
hand mounting. Undo the two bolts securing
24 Carefully withdraw the transmission from
braking system servo vacuum hoses from
the mounting bracket assembly to the vehicle
the engine. If the locating dowels are a loose
the inlet manifold (as applicable).
body, and remove the mounting bracket
fit in the engine/transmission, remove them
(e) Disconnect the exhaust system front pipe
assembly.
and keep them in a safe place.
from the manifold.
13 From underneath the vehicle, slacken and
Refitting
(f) On models with a catalytic converter,
remove the nuts and bolts securing the rear
remove the airflow meter.
mounting bracket to the mounting assembly
25 If the engine and transmission have been
and subframe, and remove the bracket.
separated, perform the operations described
All models
14 Undo the three nuts securing the
below in paragraphs 26 to 32. If not, proceed
5 Slacken the retaining clips, then disconnect
engine/transmission right-hand mounting
as described from paragraph 33 onwards.
the radiator top hose from the thermostat
bracket to the engine. Remove the single nut
26 Ensure that the bush fitted to the centre of
housing, and the radiator bottom hose from
securing the bracket to its mounting rubber,
the crankshaft is in good condition. Apply a
the water pump housing. Trace both coolant
and remove the bracket.
little Molykote G1 grease (available from your
hoses back from the heater matrix union on
15 Make a final check that all components
Citroen dealer) to the torque converter
the engine compartment bulkhead, and
that will prevent the removal of the
centring pin. Do not apply too much,
disconnect them from the engine. Also trace
engine/transmission from the car have been
otherwise there is a possibility of the grease
the small-bore coolant hoses back from the
removed or disconnected. Ensure that all
contaminating the torque converter.
left-hand right-hand side of the radiator to the
components are secured so that they cannot
27 Ensure that the locating dowels are
engine/transmission, and disconnect these
be damaged on removal.
correctly positioned in the engine or
from the engine and transmission fluid cooler.
16 Lift the engine/transmission out of the car,
transmission.
Position all hoses clear of the engine, so that
ensuring that nothing is trapped or damaged.
28 Carefully offer the transmission to the
they do not hinder the removal procedure.
Enlist the help of an assistant during this
engine, until the locating dowels are engaged.
6 Carry out the following operations, using
procedure, as it will be necessary to tilt the
29 Refit the transmission housing-to-engine
the information given in Chapter 7:
assembly slightly to clear the body panels.
bolts, ensuring that all the necessary brackets
(a) Remove the transmission dipstick tube.
Great care must also be taken to ensure that
are correctly positioned, and tighten them to
(b) Disconnect the wiring from the starter
the radiator (if not removed) and, on right-
the specified torque setting.
inhibitor/reversing light switch and the
hand drive models, the braking system master
30 Remove the torque converter retaining
speedometer drive housing. Release the
cylinder reservoir, are not damaged during the
strap installed prior to removal. Align the
earth strapfs) from the top of the
removal procedure.
torque converter threaded holes with the
transmission housing.
17 Once the engine is high enough, lift it out
retaining plate, and refit the three retaining
(c) Disconnect the selector cable.
over the front of the body, and lower the unit
bolts.
(d) Release the power steering pipe from the
to the ground.
31 Tighten the torque converter retaining
underside of the transmission.
bolts to the specified torque setting, then refit
Separation
(e) Disconnect the speedometer cable.
the driveplate lower cover.
7 Remove the right-hand driveshaft as
18 With the engine/transmission assembly
32 Refit the starter motor, and securely
described in Chapter 8.
removed, support the assembly on suitable
tighten its retaining bolts.

Engine removal and general overhaul procedures 2C*9
33 Reconnect the hoist and lifting tackle to
engine, all the external components must be
(g) Oil pump.
the engine lifting brackets. With the aid of an
removed first, to be transferred to the
(h) Piston/connecting rod assemblies
assistant, lift the assembly over the engine
replacement engine (just as they will if you are
(Section 10).
compartment.
doing a complete engine overhaul yourself).
(i) Crankshaft (Section 11).
34 The assembly should be tilted as
These components include the following:
6 Before beginning the dismantling and
necessary to clear surrounding components,
(a) Alternator mounting brackets (Chapter 5).
overhaul procedures, make sure that you have
as during removal; lower the assembly into
(b) Power steering pump and air conditioning
all of the correct tools necessary. Refer to
position in the engine compartment,
compressor brackets (where fitted)
"Tools and working facilities" at the end of this
manipulating the hoist and lifting tackle as
(Chapters 3 and 10).
manual for further information.
necessary.
(c) Distributor, HT leads and spark plugs (as
35 With the engine/transmission in position,
applicable) (Chapters 1 and 5).
refit the engine/transmission right-hand
(d) Thermostat and housing, and coolant
7 Cylinder head - dismantling
mounting bracket, tightening its retaining nuts
outlet chamber/elbow (Chapter 3).
by hand only at this stage.
(e) Dipstick tube.
Note: New and reconditioned cylinder heads
36 Refit the engine/transmission left-hand
(f) Carburettor/fuel injection system
are available from the manufacturer, and from
mounting bracket assembly to the vehicle,
components (Chapter 4).
engine overhaul specialists. Be aware that some
and tighten its retaining bolts to the specified
(g) All electrical switches and sensors.
specialist tools are required for the dismantling
torque. Refit the centre nut and washer to the
(h) Inlet and exhaust manifolds (Chapter 4).
and inspection procedures, and new
left-hand mounting, tightening it to the
(i) ACAV assembly - 1998 cc 16-valve
components may not be readily available. It may
specified torque setting. Tighten the right-
engines only (Chapter 4).
therefore be more practical and economical for
hand mounting bracket retaining nuts to their
(j) Oil filter (Chapter 1).
the home mechanic to purchase a
specified torque setting.
(k) Fuel pump - carburettor engines only
reconditioned head, rather than dismantle,
37 From underneath the vehicle, refit the rear
(Chapter 4).
inspect and recondition the original head.
mounting bracket, and tighten both its
(I) Engine mountings (Part A or B of this
1 Remove the cylinder head as described in
retaining bolts to the specified torque. The
Chapter),
Part A or B of this Chapter (as applicable).
hoist can then be detached from the engine
(m) Flywheel/driveplate (Part A or B of this
2 Remove the camshaft(s), followers and
and removed.
Chapter).
shims (as applicable) as described in Part A or
38 The remainder of the refitting procedure is
Note: When removing the external
B of this Chapter.
a reversal of the removal sequence, noting the
components from the engine, pay close
3 Using a valve spring compressor, compress
following points:
attention to details that may be helpful or
each valve spring in turn until the split collets
(a) Ensure that the wiring loom is correctly
important during refitting. Note the fitted
can be removed. Release the compressor,
routed, and retained by all the relevant
position of gaskets, seals, spacers, pins,
and lift off the spring retainer, spring and
retaining clips; all connectors should be
washers, bolts, and other small items.
spring seat. Using a pair of pliers, carefully
correctly and securely reconnected.
4 If you are obtaining a "short" engine (which
extract the valve stem seal from the top of the
(b) Prior to refitting the driveshafts to the
consists of the engine cylinder block/crank-
guide (see illustrations).
transmission, renew the driveshaft oil
case, crankshaft, pistons and connecting rods
seals as described in Chapter 7.
all assembled), then the cylinder head, sump,
oil pump, and timing belt will have to be
(c) Ensure that all coolant hoses are correctly
removed also.
reconnected, and securely retained by
their retaining clips.

5 If you are planning a complete overhaul, the
(d) Adjust the selector cable and kickdown
engine can be dismantled, and the internal
cable as described in Chapter 7, Part B.
components removed, in the order given
below, referring to Part A or B of this Chapter
(ej Adjust the accelerator cable as described
unless otherwise stated.
in Chapter 4.
(a) Inlet and exhaust manifolds (Chapter 4).
(f) Refill the engine and transmission with
(b) ACAV assembly-1998 cc 16-valve
correct quantity and type of lubricant, as
engines only (Chapter 4).
described in Chapter 1.
(c) Timing belt, sprockets and tensioner(s).
(g) Refill the cooling system as described in
(d) Cylinder head.
Chapter 1.
(e) Flywheel.
(f) Sump.

7.3a Compress the valve spring using a
6 Engine overhaul -
spring compressor . . .
dismantling sequence
1 It is much easier to dismantle and work on
the engine if it is mounted on a portable
engine stand. These stands can often be hired
from a tool hire shop. Before the engine is
mounted on a stand, the flywheel/driveplate
should be removed, so that the stand bolts
can be tightened into the end of the cylinder
block/crankcase.
2 If a stand is not available, it is possible to
dismantle the engine with it blocked up on a
sturdy workbench, or on the floor. Be extra-
careful not to tip or drop the engine when
working without a stand.
7.3b . . . then extract the collets and
3 If you are going to obtain a reconditioned
release the spring compressor
7.3c Remove the spring retainer .

2C*10 Engine removal and general overhaul procedures
7.3d . . . followed by the valve spring . . .
7.3e . . . and the spring seat
7.3f Remove the valve stem oil seal using
a pair of pliers
4 If, when the valve spring compressor is
3 Scrape away the carbon from the
the thermostat housing area. These heads
screwed down, the spring retainer refuses to
combustion chambers and ports, then wash
have had 0.2 mm machined off the gasket
free and expose the split collets, gently tap
the cylinder head thoroughly with paraffin or a
face. When fitting to the engine, a slightly
the top of the tool, directly over the retainer,
suitable solvent.
thicker head gasket should be used (see
with a light hammer. This will free the retainer.
4 Scrape off any heavy carbon deposits that
Part A or B for further information).
5 Withdraw the valve through the combustion
may have formed on the valves, then use a
chamber.
7 Examine the valve seats in each of the
power-operated wire brush to remove
combustion chambers. If they are severely
6 It is essential that each valve is stored
deposits from the valve heads and stems.
pitted, cracked, or burned, they will need to
together with its collets, retainer, spring, and
be renewed or re-cut by an engine overhaul
spring seat. The valves should also be kept in
Inspection
specialist. If they are only slightly pitted, this
their correct sequence, unless they are so
Note: Be sure to perform all the following
can be removed by grinding-in the valve
badly worn that they are to be renewed. Note
inspection procedures before concluding that
heads and seats with fine valve-grinding
that No 1 valve is nearest to the transmission
the services of a machine shop or engine
compound, as described below. Note: It is
(flywheel/driveplate) end of the engine.
overhaul specialist are required. Make a list of
not possible to renew the valve seats on the
all items that require attention.
1998 cc 16-valve engine.
Cylinder head
8 Check the valve guides for wear by
inserting the relevant valve, and checking for
5 Inspect the head very carefully for cracks,
side-to-side motion of the valve. A very small
evidence of coolant leakage, and other
amount of movement is acceptable. If the
damage. If cracks are found, a new cylinder
movement seems excessive, remove the
head should be obtained.
valve. Measure the valve stem diameter (see
6 Use a straight-edge and feeler gauge blade
below), and renew the valve if it is worn. If the
to check that the cylinder head surface is not
valve stem is not worn, the wear must be in
distorted (see illustration). If it is, it may be
the valve guide, and the guide must be
possible to have it machined, provided that
renewed. The renewal of valve guides is best
the cylinder head is not reduced to less than
carried out by a Citroen dealer or engine
the specified height. The cylinder head height
overhaul specialist, who will have the
is measured from the centre of the cylinder
necessary tools available. Where no valve
If the valve and its associated
head camshaft bore to the cylinder head
stem diameter is specified, seek the advice of
components are going to be used
gasket face. Note: Cylinder heads that have
a Citroen dealer on the best course of action.
again, place each valve assembly in a
had their gasket surface refaced by Citroen
9 If the valve seats are to be re-cut or re-
labelled polythene bag or similar small
will be stamped with an "R" somewhere on
ground, this must be done only after the
container.
the left-hand end of the cylinder head, around
guides have been renewed.
8 Cylinder head and valves -
cleaning and inspection
1 Thorough cleaning of the cylinder head and
valve components, followed by a detailed
inspection, will enable you to decide how
much valve service work must be carried out
during the engine overhaul. Note: If the
engine has been severely overheated, it is best
to assume that the cylinder head is warped -

check carefully for signs of this.
Cleaning
2 Scrape away all traces of old gasket
material and sealing compound from the
8.6 Checking the cylinder head gasket
8.11 Measuring a valve stem diameter
cylinder head.
surface for distortion