Gearbox removal & installation: Xsara Picasso (DV6TED4 engine) — CITROEN

🔧 Engine codes this applies to

📋 Procedure

1. Drive shaft seal fitting tool(s)
2. Use the special tools
3. Check that the dowel pins/sleeves for centering the engine/gearbox are still in place
4. Speedometer drive:
5. Starter motor:

6. Remove the air filter inlet hose
7. Disconnect the cables from the battery clamp
8. Mechanical clutch control:
9. Disconnect the clutch cable from the bracket and release lever
10. Disconnect the clutch cable
11. Secure to the vehicle
12. Hydraulic clutch control:
13. Unclip the clutch hydraulic line
14. Remove the clutch cylinder from the gearbox but do not disconnect the hydraulic system
15. Secure to the vehicle
16. Unclip the wiring from the gearbox
17. Remove the support
18. Disconnect the sensor
19. Disconnect the reversing light switch from the gearbox
20. Disconnect the earth cable from the gearbox
21. Disconnect the rev counter
22. Disconnect the TDC sensor
23. Disconnect the gear-shift cables from the gearbox
24. Remove the gear-shift control bracket
25. Vehicles with air conditioning:
26. Disconnect the connector
27. Remove the air-conditioning drive belt
28. Remove the air-conditioning compressor but do not disconnect
29. Lift out the air-conditioning compressor and secure it
30. Vehicles with diesel particulate filter
31. Disconnect both exhaust gas temperature sensors
32. All vehicles:
33. Remove the heat shield(s)
34. Remove the retaining sleeve
35. Remove the clamp
36. Remove the nuts
37. Remove the catalytic converter
38. Remove the studs
39. Remove the bolt
40. Remove the reaction link
41. Remove the rubber buffers
42. Remove the power steering pressure line bracket
43. Remove the flywheel inspection cover plate
44. Remove the starter motor
45. Remove the bolt
46. Note: Disconnect the reservoir and place it aside
47. Remove the speedometer drive
48. Use a hoist to support the engine and gearbox
49. Remove the bolt
50. Remove the gearbox support
51. Remove the gearbox support bracket
52. Remove the engine/gearbox attaching bolts
53. Separate the gearbox from the engine
54. Remove the gearbox

Other CITROEN procedures

• DV6TED4/ATED4/BTED4 engine - camshaft chain
• DV6TED4/ATED4/BTED4 engine - camshaft chain
• C5 DV6TED4 (incl MY08)
• C4 Picasso DV6TED4
• 307 1.6 HDi DV6TED4 (ATED4/TED4B)
• std HDi single bolt camshaft gearwheel
• std HDi 3 bolt camshaft gearwheel
• Xantia XUD9 non turbo
• Xantia XUD9T turbo
• C5 EW7J4, EW10J4 (Crankshaft locking at flywheel 2004->)