Changing the XUD9 diesel engine on a Citroën BX Van.
The old diesel engine was working quite well with more than 700 000 km on the clock, but the water pump, which had only 10 % of that, decided to break its bearings, resulting into a slipped timing belt and a camshaft in three pieces. The Old Lady was towed home, rear wheels were placed on ramps, front end lifted, and then it was time to have some engine changing fun.
Brake disks were removed, the lower support arm ball joints and the anti roll bar links were opened, drive shafts removed..
..coolant, engine oil and gearbox oil were drained..
..and a good documentation round was made through the wiring. Special attention was due around the alternator and starter..
..oil pressure warning sensor..
..the battery (note the personal wiring arrangement for the glow plug relay!)..
..and the thermostat housing.
The slipped timing belt can be seen on the starboard side of the engine.
After removing the radiator and the fan..
..there's plenty of room to have fun on the port..
..front..
..and starboard side of the engine. The rear is still a bit cramped, but accessible from underneath the car, especially after removing the starboard side driveshaft.
The on-the-road-fix on the throttle cable (made from a hose clip and an 8 mm socket) has lasted for 5 years, and will now be replaced with a proper end.
The bonnet is on the way..
..so it shall be removed.
After taking off all hydraulics components fixed to the engine, the alternator, exhaust pipe, as well as all electrical wiring and the cables, it's time to drive the Belarus into position..
..and carefully remove the engine using the manual hoist until it clears the engine bay..
..and then lift it..
..to a proper intermediate storage.
After repeating the engine removal exercise with the donor car, the "brand new" XUD9 is..
..lifted to the outfitting facilities for installation of the required hoses and fittings.
Then it is gently slipped in place..
..where it nicely fits. Since the hitch of the old Belarus is what it is, the fine-mechanical part of the engine wrestling is made with the manual hoists, and keeping the more important fingers clear from narrow places.
After securing the clutch fork pin..
..and filling the gearbox with proper oil, all previous steps are repeated in reversed order, and the Old Lady is ready for new adventures.