Changing the XUD9 diesel engine on a Citroën BX Van.
Top
Left 000-IMG_2194.JPG.small.jpeg Right
Bottom
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.

Top
Left 001-IMG_2196.JPG.small.jpeg Right
Bottom
Brake disks were removed, the lower support arm ball joints and the anti roll bar links were opened, drive shafts removed..

Top
Left 002-IMG_2198.JPG.small.jpeg Right
Bottom
..coolant, engine oil and gearbox oil were drained..

Top
Left 003-IMG_2199.JPG.small.jpeg Right
Bottom
..and a good documentation round was made through the wiring. Special attention was due around the alternator and starter..

Top
Left 004-IMG_2202.JPG.small.jpeg Right
Bottom
..oil pressure warning sensor..

Top
Left 005-IMG_2203.JPG.small.jpeg Right
Bottom
..the battery (note the personal wiring arrangement for the glow plug relay!)..

Top
Left 006-IMG_2204.JPG.small.jpeg Right
Bottom
..and the thermostat housing.

Top
Left 007-IMG_2206.JPG.small.jpeg Right
Bottom
The slipped timing belt can be seen on the starboard side of the engine.

Top
Left 008-IMG_2208.JPG.small.jpeg Right
Bottom
After removing the radiator and the fan..


Top
Left 009-IMG_2209.JPG.small.jpeg Right
Bottom
..there's plenty of room to have fun on the port..

Top
Left 010-IMG_2211.JPG.small.jpeg Right
Bottom
..front..

Top
Left 011-IMG_2213.JPG.small.jpeg Right
Bottom
..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.

Top
Left 012-IMG_2215.JPG.small.jpeg Right
Bottom
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.

Top
Left 013-IMG_2217.JPG.small.jpeg Right
Bottom
The bonnet is on the way..

Top
Left 014-IMG_2218.JPG.small.jpeg Right
Bottom
..so it shall be removed.

Top
Left 015-IMG_2219.JPG.small.jpeg Right
Bottom
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..

Top
Left 016-IMG_2221.JPG.small.jpeg Right
Bottom
..and carefully remove the engine using the manual hoist until it clears the engine bay..

Top
Left 017-IMG_2222.JPG.small.jpeg Right
Bottom
..and then lift it..

Top
Left 018-IMG_2224.JPG.small.jpeg Right
Bottom
..to a proper intermediate storage.

Top
Left 019-IMG_2225.JPG.small.jpeg Right
Bottom
After repeating the engine removal exercise with the donor car, the "brand new" XUD9 is..

Top
Left 020-IMG_2227.JPG.small.jpeg Right
Bottom
..lifted to the outfitting facilities for installation of the required hoses and fittings.

Top
Left 021-IMG_2229.JPG.small.jpeg Right
Bottom
Then it is gently slipped in place..

Top
Left 022-IMG_2233.JPG.small.jpeg Right
Bottom
..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.

Top
Left 023-IMG_2237.JPG.small.jpeg Right
Bottom
After securing the clutch fork pin..

Top
Left 024-IMG_2239.JPG.small.jpeg Right
Bottom
..and filling the gearbox with proper oil, all previous steps are repeated in reversed order, and the Old Lady is ready for new adventures.