Citroen BX restoration

bludenz

Member
Tadpole
Tadpole
Joined
Jan 28, 2024
Messages
51
Location
Western Australia
Hi All,

Hoping you can help out a young Citroen enthusiast! I'm currently still in high school and in the midst of restoring my 1987 Citroen BX (diesel, manual, XUD9, series 2 if that makes any difference). Some background information:

I originally picked up this BX back in 2021 from an older gentleman - I think I paid $500 or so for the car so it is definitely not in show room condition. It had been sitting parked on his property for who knows how long... Thankfully, it's escaped any visible rust, but the engine is unfortunately seized solid. I do have a second engine, but sadly that one has not escaped unscathed either, as it is severely scored in one cylinder. For this post though, the only relevance that the engine has is that I'm in the process of pulling the seized one out, cleaning up the engine bay, and getting ready for an engine install later this year once I've (hopefully) rebuilt one of them.

Today I was removing the driver's side driveshaft, having already disconnected most of the hoses and pipes in the engine bay. While taking things apart, I've noticed a few bits my (sadly unregistered) BX would likely need to pass pits here in WA:

- New tie rod ends (or at least the rubber boot where the tie rod joins the steering rack)
- New rubber boot on the bottom of the strut (the one that makes contact with the lower control arm)
- New rubber boots for the drop link as well – if the whole link is replaceable, I'd definitely consider that.
- New driveshaft boots for both sides
- Likely new rubbers for the shocks, however I haven't fully inspected these yet.
- New rotors (I think Supercheap Auto might have some that fit, but if not, I can definitely source a set from Europe)

These are just the front suspension components; I am yet to look at the rear end of the BX before I'm off to Europe in July.

As mentioned, I'm heading off to Europe in July. Besides a holiday, I am really hoping to find some of these parts – ideally NOS or used in great condition. Some of the eBay prices I've seen are a bit eye-watering for my budget, so I'm wondering if any other BX enthusiasts have any useful knowledge or tips on where to source parts or even how to refurb my existing parts (hence me mentioning only replacing rubber boots as opposed to entire components, would likely be cheaper)

I'm lucky enough to have access to some fantastic tools, including a lathe, plasma cutter, sandblaster, and metal benders at my school, meaning I can clean up existing parts pretty easily and even machine parts, or special tools if needed. However, I do not have access to a hoist so some of the work is a little more difficult.

Once the engine and transmission are out of the way, I'm also planning to refurbish some of the hydraulic system. The "octopus" hose, as I believe it's called, is split in multiple places, especially where the smaller lines branch off from the main line, near the hydraulic fluid reservoir. I'll likely add some photos of my progress when I get some time this weekend.

I'm sure I'll have a lot more questions as my restoration progresses, but currently any advice, leads on parts suppliers (especially in Europe), or general BX wisdom you can share with a young restorer would be hugely appreciated!

Cheers,
Elliott
 
Bon Courage! The BX is in that twlight zone between common, mass produced car and collectable 'modern classic'. Dealers and motor factors have long since topped stocking parts but there's not yet the demand/value for lots of reproduction parts. If any of the rubber parts you have are in the least bit servicable, keep them. Where repro parts have been available the quality of the rubber has been very variable. If you're going to be in France at all start checking out Leboncoin. In my experience French sellers are very reluctant to ship overseas but if you're in France it's worth a shot. You can also try BXParts in the Netherlands or Chevronics in the UK.
 
First step is to grab yourself a copy of the BX parts manual. It's available from a few places online as a PDF. You can then punch the part numbers into spareto.com, Alvadi and a few other big online retailers who stock a surprisingly large array of parts for the BX with pretty reasonable prices and shipping. For some things you can also still call a Peugeot dealer, quote the part numbers and they'll bring them in. Prices aren't always as crazy as you'd expect because the BX shares parts with 405s and the XU9 engine/BE3gearbox combo is essentially still in production.

If you want NOS parts then be prepared to pay for them. Most NOS general service items like boots, linkages, dizzy caps etc are long gone or have been hoarded by a few who want a kings ransom for them. For instance you can get driveshaft boots in Peugeot boxes for 50GPB each or Febi Bilstein OEM ones for half that. Same with wheel bearing kits and a ton of other parts.

Trim is going to be the hardest to source so go easy with the interior plastics and exterior trim.

Some of the more Citroen specific parts like front strut rebuild kits are totally NLA and there is no substitute for them. If the front struts are sticky then you either have to live with it or find a set of better ones to swap in.

The octopus can be remade pretty simply with a few brass T joiners and some 4mm fuel hose for about half the cost of a new one. This also has the benefit of when it next fails, you don't have to chuck out the perfectly fine 2/3 along with the broken leg.

There are a few UK based Citroen/Peugeot forums that are worth joining. If you ask around there for parts you're more likely to strike gold.

Chevronics and BXparts are pretty good to deal with and I've heard good things about garage80. Shipping to AUS is what kills the prices but if youre in the UK or Netherlands then stop by and talk to them.
 
Did you try freeing the motor up? The rings might just have a tiny bit of rust holding them to the bores.... dump something like ATF/deisel down the glow plug holes for a few days and try moving it.
 
Did you try freeing the motor up? The rings might just have a tiny bit of rust holding them to the bores.... dump something like ATF/deisel down the glow plug holes for a few days and try moving it.
I've tried heat, diesel, wd40, oil, vinegar, etc... (head has been removed, the gentle man who is bought it off said it was a blown headgasket, clearly not) I'm at the point now where the sump is off, all the con rod caps are off (numbered and marked) and I've tried using a wood block with a hammer to move the pistons. No luck so far, they refuse to budge. There is no visible corrosion on the bottom end either. Bores (above the pistons, all are stuck in the center i guess i would call it) have some surface rust on it.

Now the pistons are no longer connected to the crank, and it still refuses to turn over, both the pistons and the crank refuse to move. I'll upload some pictures soon.
 
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Some photos of the seized engine in the car, the liquid in the bores is wd40 this time. Was hoping that they would move once disconnected from the crank but apparently not. I'll post some pictures of the suspension later
 

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Edit to add that I've removed the starter and it is still seized solid :(

Attached are pictures of the driver's side suspension, the tie rod end doesn't even have a boot on it (crumbled apart), the rotor is rusted to the point where it is pitted, and who knows about the brake pads, I haven't hmgotten a chance to inspect those yet
 

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The XUD9 engine also can be found in the Peugeot 405, which may help looking for now hard-to-find parts.

With the dry pistons seized, I'd be worried about the injection pump too. There are two kinds, Bosch or Roto (CAV).

PS Don't be tempted to open up an injection pump. Super cleanliness is essential.
 
The XUD9 engine also can be found in the Peugeot 405, which may help looking for now hard-to-find parts.

With the dry pistons seized, I'd be worried about the injection pump too. There are two kinds, Bosch or Roto (CAV).

PS Don't be tempted to open up an injection pump. Super cleanliness is essential.
I have the bosch injection pump. I do have a spare but to my knowledge neither is seized, I'll test and confirm this again soon.

The websites that @IanA and @faulksy mentioned seem to have affordable prices for parts, but thanks for the heads up with the Peugeot 405
 
nice old car you've rescued !
wow, its been badly mistreated though
but the XUD9 is a great engine and the bosch pumps are great
and hopefully he didn't wreck the BE3 gearbox which are good

BX carparts catalog is online here :


its got all your part numbers which you will need to refer to when searching
they also cross models which simplifies it
and the diagrams are good too
and write down your build date to refer to when checking the catalog as there's an early and later version of the XUD9
as mentioned above, the XUD9 was in other citroen and peugeot models
peugeot - 205, 306, 309, 405
citroen - berlingo, zx, and others

very very likely the bosch injection pump(s) will need to be rebuilt
they dry out/gum up after a few months off the car
even more so with the injectors

serie04 and the peugeot shop (both in France) will also be good for your engine parts
leboncoin has tonnes of good stuff if u can find a way to buy it from the sellers over in France
 
Thanks for the information. I did not know that there was an earlier and later version of the XUD9 engine :)

Thankfully I have 2 spare gearboxes, and one more in the car (3 total) so if the one in my car is broken I'm hoping that the other two are not.

Thanks for the heads up with the injection pump as well, I may bring one to Europe with me to get it rebuilt there, as labour for these kind of things seems to be cheaper in europe than it is here.

Thanks again
 
also recommend getting the engine/tranny out asap (probly before taking it apart)
and get a used engine stand for it

it'll take time now but will make it a lot easier over time
 
Hopefully they are coming out tomorrow. Already been taken apart somewhat as its seized and I'm assuming that the bores are gone as they show signs off pitting from rust etc...

I have a second engine that I've started to rebuild (read previous posts for more info) so I'm planning to use the engine in the car as a reference point on where all the accessories and things go on the engine.

Thankfully I already have an engine stand available : )
 
i've got a Peugeot Workshop Manual for XUD7 & XUD9 Engine Rebuild

if you'd like a copy I could try and email it over
 
nah yours is different, looks pretty good though

mines what peug mechanics used to have in a big folder in their shop

PM your email
 
Fantastic learning experience and a great project for a young guy of your age, all power to you. You are learning fast! Keep us posted! A mixture of auto trans fluid and nail polish remover (whatever the stuff that's in that!) shifts things pretty well. Tapping a block of wood on those pistons. Might help
 
Thanks for the advice. Hoping I can get the passenger side drive shaft out this afternoon and then remove the engine and remove those pistons that have caused me such a headache. I'm hoping that the crank is not seized.

Has anyone imported an engine from abroad before? I think importing a complete working engine from Europe might be cheaper than getting one of my engines machined, etc...
 
can you find a peugeot 405 locally with the motor in it ? that would be an easier option
 
can you find a peugeot 405 locally with the motor in it ? that would be an easier option
I have been keeping a look out. There was a guy 4 hours south from me who was selling 2x 405's (turbo diesel). Unfortunately both engine's suffered snapped timing belts and I didn't want to drive 8 hours (there and back) just to be disappointed, plus, they would have needed to be rebuilt as well so I don't think it would have been worth it.
 
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