Gearbox removal & installation: Citroen Xsara Picasso 1997cc motor (DW10TD)

🧭 Before you start

• Opens: coolant, power steering fluid, gearbox oil, fuel

🔧 Engine codes this applies to

📐 57 workshop diagrams for DW10TD(RHY)

Real factory drawings for this job — timing marks, bolt locations and routing. Locked in the free view.

📋 Procedure

1. Before disconnecting the battery cable, check the audio system security code
2. The engine and gearbox are removed as a unit
3. Front drive shaft to wheel bearing housing:
4. Remove the mass airflow meter
5. Remove the air filter unit support

6. Disconnect the vacuum pump hose
7. Remove the front wheels
8. Loosen the drive shaft nuts
9. Remove the inner wings
10. Remove the V-belt
11. Drain the cooling system
12. Drain the power steering fluid
13. Drain the gearbox oil
14. Remove the subframe
15. Disconnect the air-conditioning compressor electrical connections
16. Disconnect the air-conditioning pump from its support
17. Disconnect the power steering pump lines
18. Remove the clutch cover
19. Disconnect the turbocharger air hose from the mass airflow meter
20. Disconnect the gearbox operating linkage
21. Remove the heater hoses
22. Disconnect the hose
23. Disconnect the wiring and hoses from the throttle housing
24. Disconnect the lower radiator hose
25. Disconnect the upper radiator hose
26. Disconnect the clutch cable
27. Disconnect the throttle potentiometer
28. Disconnect the gearbox earth connection
29. Disconnect the starter motor wiring
30. Disconnect the fuse box
31. Disconnect the connector(s) from the solenoid valve
32. Disconnect the glow plugs
33. Disconnect the relays
34. Remove the injection management unit
35. Loosen
36. Disconnect the engine wiring loom
37. Raise the vehicle
38. Support the engine
39. Disconnect the fuel lines
40. Release the wiring
41. Remove the bracket
42. Retaining nuts:
43. Remove the bolts
44. Remove the flange
45. Remove the nut
46. Remove the engine/gearbox

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