Xsara Picasso 1.6 HDi Clutch Replacement HELP!

[bigtone0777]

Hi Guy's, I hope you can help me as I'm wishing I hadn't started this job lol

I'm trying to remove the gearbox to replace the clutch but I'm having a bit of trouble.

I've removed 2 starter bolts either side of the solenoid but can't even feel the third let alone see it, any tips for this?

Also up top I'm struggling to remove the bracket which holds the harness under the thermostat housing. It seems like the thermostat housing is in the way of the screws, does the thermostat housing really need to be removed?

Is there anything else I need to watch out for?

Thanks in advance for any help and advice!

[RichardW]

There's a 3rd bolt under the thermostat housing into the starter - you can't see it except with a mirror. And there might be a nut on the gearbox side opposite the solenoid.

Don't know about the 'stat housing; I can have a look later and see if there is any reference in the instructions

You do know that there is a bolt inserted from the engine side behind the Cat / DPF cannister, so you need to remove this to get this bolt out? This may involve removing the rad....(but it's easier on a car without a DPF, so maybe not in your case) although somehow the guy that did the clutch on our (DPF equipped) C4 Picasso managed to get the DPF out of the way enough to get the bolt out without removing the rad - I've no idea how, I couldn't even get the heat shield off! Whilst you are there pop the bottom banjo bolt out of the turbo oil feed and remove the strainer from the end of it to minimise the chance of the turbo eating itself!

[bigtone0777]

Thanks Richard.

I've now got the 3rd starter bolt out and just about everything around the bell housing now so hopefully I'm about there.

The cat is easy to get off on mine as the heat shields are already off due to them rotting away, need to get some new ones.

I already sorted the turbo oil feed pipe when I first got the car so we're all good there.

Thanks for the advice.

I'll post up once the box hits the floor

[bigtone0777]

I was wrong, it does have the heat shields on so I have to take the radiator out

[RichardW]

If there's no DPF, then it's not too bad to get the bolts out the heat shield with the rad in - I couldn't get the shield out past the turbo,but actually it was just an 'ear' on the shield that wouldn't take long to remove... worth a try to avoid having to drain the coolant!

[bigtone0777]

I've took the rad out now but the good news is the gear box is now out! To my surprise I found the pressure plate bolts were loose, that would explain why it started slipping so badly within 1 day!
There's a fair bit more work involved compared to the 2.0 HDi.