Citroen Xsara 1998 - XUD inlet manifold removal

Honest John Back Room » Technical matters
View Threaded
Wed 1 Dec 2010 12:18
Citroen Xsara 1998 - XUD inlet manifold removal - orchid4

I need to remove the cylinder head (with the engine in-car) and so must remove the inlet manifold before getting to remove the exhaust manifold.

Access to all the bolts is very poor, but one of them needs me to remove the EGR unit first, as Haynes says. BUT I am finding it impossible to get a hex key to the front EGR bolt because the inlet manifold is in the way.

Is there a way around this or is there a special tool? I am thinking of bending an Allen key to a useful angle (in frustration??). I thought of just removing the EGR pipe which might give enough room, but the clip is crimped on and I can't get access to cut that off.

I have never worked on such an awkward engine. Can anyone help?

Thanks, Phil

(PS - apologies for posting twice: a sever crash made me think it hadn't posted first time - maybe the moderator will remove one)

Edited by orchid4 on 01/12/2010 at 12:21

Reply | Report as offensive | Link
Wed 1 Dec 2010 13:26
Citroen Xsara 1998 - XUD inlet manifold removal - tdc

Is access possible from underneath the car whilst jacked up/on ramps,hopefully you`re under cover?! I find that this is the only way to get at some things on the transverse engine layout.Think I had to do this to remove a turbo on a Golf once and lots of awkward little jobs on other vehicles.You`ll need a good lead-light.

...or from under the bonnet,can you snip the crimped clamp with side cutters,is the sticky-outy bit where you can reach it?I use slim-line jubilee clips to replace original crimped ones.

Wont an allen attachment using a 3/8 socket set with universal-joint work?

Reply | Report as offensive | Link
Wed 1 Dec 2010 13:59
Citroen Xsara 1998 - XUD inlet manifold removal - orchid4

Hi TDC - thanks for the quick reply.

No, I'm not undercover, so fingers are slow and clumsy in current temperatures. I could raise front to work from underneath but am sure won't be able to reach the EGR valve from there, especially its front bolt which is the problem one.

I have not managed to get snips to the clamp, but have decided to try a saw blade.

Yes, I have tried a UJ and socket allen key but the angle is poor causing the UJ to twist over, which with the old and slightly corroded bolt head results in no effective purchase.

I think pulling the engine out may be the best way forward <sigh>

Reply | Report as offensive | Link

From choosing the right tyre to what to do when it goes wrong - we have the answers.

Tyre News And Advice