How To Change A Clutch On A Citroen Xsara Picasso?

How To Change A Clutch On A Citroen Xsara Picasso
Replacing the clutch is not really an easy do-it-yourself maintenance since you need good knowledge of general mechanics as well as special tools for centering the disc and the disc pusher; having said this, it is advisable to lift the car on a bridge rather than on car stands to have more room for maneuver; then disconnect the battery and release the drive shaft on the gearbox side from the wheel hub to be able to extract it from the gearbox itself; then remove the gearbox from the engine and

How long does it take to replace a Citroen Xsara Picasso clutch?

1-24 of 24 results for Citroen Xsara Picasso, Clutch Replacement in the UK Part brands: AP, Citroen, LUK Labour time: 5-6 hours Part brands: AP, Citroen, Valeo Labour time: 5-6 hours Part brands: AP, Citroen, LUK Labour time: 5-6 hours Part brands: AP, Citroen, Valeo Labour time: 5-6 hours Part brands: AP, Citroen, LUK

How do you fit a new clutch disc to a car?

Slide the new clutch plate – Before fitting the new clutch disc, make sure the input shaft is clean and free from any wear. Smear a little high melting point grease on the splines then slide the new clutch plate up and down the splines a couple of times, remove the plate and wipe any excess grease off.

How to grease a clutch plate?

In this month’s Clutch Clinic, Schaeffler REPXPERT Alistair Mason is replacing the clutch assembly on a 2007 Citroën C4 Grand Picasso, fitted with a 1.8L 16-valve petrol engine that has covered more than 142,000 miles. – T he customer had reported clutch slip and after the problem was confirmed, the vehicle was booked in.

Following best practice, the parts were ordered ready for the job, the service information and technical bulletins were checked on REPXPERT prior to the repair, and the repair instructions and torque settings were also printed in advance. With a scheduled time of 9.7 hours and only basic workshop equipment required, this repair is achievable below the scheduled time, so will make a profitable job for any independent workshop.

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Advised workshop equipment

Vehicle lift (two-post is ideal) Engine support Transmission jack Clutch alignment tool

Gearbox removal With the vehicle on the ramp, open the bonnet and raise the vehicle to gain access to the underside. Remove the engine undertray and lower the vehicle to waist height, remove the N/S/F wheel and hub nut, followed by the N/S/F wheel arch liner. How To Change A Clutch On A Citroen Xsara Picasso Lower the vehicle to gain access to the engine bay (Fig 2), remove the air box assembly, battery and tray, this now gives good access to the top of the gearbox, so the multiplugs for the reverse light switch and the crank speed sensor can be disconnected. How To Change A Clutch On A Citroen Xsara Picasso Unclip the battery to the engine wiring loom and disconnect the retaining bracket to give better access to the top bell-housing bolts, then remove the upper bell-housing bolts, disconnect the gear change cables and remove the crank sensor. Raise the vehicle to gain access to the underside and remove the N/S sub-frame leg (Fig 3). How To Change A Clutch On A Citroen Xsara Picasso Now, disconnect the gearbox pendulum mount (Fig 4), as this will allow the engine to move, and remove the gearchange cable bracket. How To Change A Clutch On A Citroen Xsara Picasso Tip – Whilst in this area, remove the O/S driveshaft seal housing, as this will eliminate the need to remove the O/S driveshaft (Fig 5). Remove the lower bellhousing bolts, leaving one easily accessible to support the gearbox. How To Change A Clutch On A Citroen Xsara Picasso Support the engine and remove the gearbox mounting and carefully lower the gearbox and engine assembly slightly to aid gearbox removal. Support the gearbox with a transmission jack, remove the final bellhousing bolt, and ease the gearbox away from the engine.

Once clear, lower the gearbox and remove it from the vehicle. Clutch replacement Before removing the clutch, it is advisable to remove any excess clutch dust with some brake and clutch dust cleaner. Tip – It is good practice to note the position of the clutch components as they are removed as this may help with correct installation.

Remove the six clutch pressure plate bolts and then the clutch pressure plate and clutch plate assembly. This vehicle is fitted with a solid, single mass flywheel, the surface of which must be inspected for any heat cracks. Provided that it’s OK, remove any glaze from the flywheel surface with an Emory cloth, and clean with brake and clutch dust cleaner. How To Change A Clutch On A Citroen Xsara Picasso Remove the clutch release arm and release bearing, and inspect the release bearing guide tube for any wear (Fig 7), as well as the release arm and release arm pivot. In this instance, wear was evident, so the guide tube, arm and pivot were all replaced. How To Change A Clutch On A Citroen Xsara Picasso Check the bell-housing area for any oil leaks, and repair if required, then clean with brake and clutch dust cleaner. Fit the release bearing onto the guide tube and locate it into the release arm (Fig 8). Now, apply a light smear of high melting point grease to the splines on the gearbox input shaft and slide the clutch plate onto the input shaft. How To Change A Clutch On A Citroen Xsara Picasso Now, install the new clutch assembly onto the flywheel. Using a clutch alignment tool, and with the ‘Gearbox side’ on the clutch plate indicating its correct position (Fig 9), locate the clutch plate onto the flywheel, dowels. Install the bolts and tighten evenly and sequentially, and then torque to the manufacturer’s specification. How To Change A Clutch On A Citroen Xsara Picasso Gearbox installation To aid installation, ensure the gearbox alignment dowels are located in the engine, and all cables and brackets are clear. Using the transmission jack, bring the gearbox close to the engine, and, if necessary, spend some time aligning the gearbox before easing it into position until it is aligned on the dowels and mated to the engine.

Insert a couple of easily accessible bell-housing bolts and tighten to secure the gearbox to the engine. Installation is in the reverse order of removal. Torque all bolts to the manufacturer’s specification, refill the gearbox with the correct specification and quantity of oil, and reset the required electrical consumers after the battery is reconnected.

Finally, always carry out a road test to ensure you have completed a quality repair. Information on Schaeffler products, fitting instructions, labour times and much more can be found on the REPXPERT workshop portal the REPXPERT app, or by calling the hotline on 0872 737 0037.

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Is the Citroen Xsara Picasso a good MPV?

The Citroen Xsara Picasso is one of the most popular MPV vehicles on the road. With well over 230,000 vehicles in the UK. LuK, a brand of Schaeffler Automotive Aftermarket, takes a closer look at the clutch replacement on the 2.0hdi model. – If the vehicle is fitted with alloy wheels make sure the locking key is available before starting the job. Disconnect the reverse light switch and the earth lead connection which is found on the gearbox. The excess wiring loom can be secured to the body using a bungee cable. It is possible to remove the top two bell housing bolts and three starter motor bolts.

The gearbox mount centre bolt can be slackened while the vehicle is at ground level, but do not remove it completely. Raise the vehicle and remove the engine under-tray. Support the engine and gearbox using the transmission jacks. When supporting the engine do so from under the sump and use a wood block to protect it.

Drain the gearbox oil, remove N/S front wheel, remove the N/S ball joint bolt and detach from its position.