How to use this chapter
IN chapter 2B describes repair procedures that it is reasonable to carry out without removing the engine from the vehicle. If this information is used during the overhaul of an engine that has already been removed and installed on the stand (see chapter 2E), preliminary disassembly operations can be skipped.
Keep in mind that while some items, such as piston and connecting rod assemblies, can be removed and repaired without removing the engine from the vehicle, these procedures are usually not performed as separate operations. As a rule, several additional procedures are performed simultaneously (not to mention the cleaning of elements and lubrication grooves). Therefore, all such procedures are considered to be overhaul items and are described in chapter 2D.
IN chapter 2D describes the removal of the engine/transmission from the vehicle and any overhaul procedures that can be performed after the engine has been removed.
Engine design
The XUD series engine is a field-proven unit that has already been used in many Peugeot and Citroen vehicles. It is an in-line four-cylinder engine with a single overhead camshaft (SOHC). The engine is transversely mounted at the front of the vehicle. The gearbox is bolted to the left end of the engine.
The timing belt drives the camshaft, high pressure fuel pump and coolant pump. Pushers are installed between the camshaft and valves. Valve clearances are adjusted using shims. The camshaft is supported by three bearings which are bored directly into the cylinder head.
The crankshaft runs in five plain bearings. Main bearing No. 2 is equipped with thrust washers to set the axial clearance of the crankshaft.
Pistons are selected by weight. In the pistons, fully floating piston pins are fixed with retaining rings.
Engine lubrication is provided by an oil pump, which is chain driven from the front end of the crankshaft. All engines have an oil cooler designed to cool the engine oil.
In this manual, engines are often identified not only by displacement, but also by the engine code. The engine code consists of three characters (e.g. D9B). The code is stamped on a plate attached to the front of the cylinder block.
Repair operations performed without removing the engine from the vehicle
Without removing the engine from the car, you can perform the following operations:
- A) compression test and leak test;
- b) removal and installation of the cylinder head cover;
- V) removal and installation of the crankshaft pulley;
- G) removal and installation of timing belt covers;
- d) removal, installation and adjustment of the timing belt;
- e) removal and installation of the tensioner and toothed pulleys of the timing belt;
- and) replacement of the sealing cuff of the camshaft;
- h) removal, inspection and installation of the camshaft and pushers;
- And) checking and adjusting valve clearances;
- To) removal and installation of the cylinder head;
- l) removal of carbon deposits from the cylinder head and pistons;
- m) removal and installation of the oil pan;
- n) removal, repair and installation of the oil pump;
- O) replacement of crankshaft seals;
- P) inspection and replacement of engine/gearbox mounts;
- R) removal, inspection and installation of the flywheel.