B1CJ0BK1 - 406D9 XU INJECTION

REASSEMBLY ENGINE (CYLINDER BLOCK)

1 - SPECIAL TOOLS

2 - REFITTING THE PISTON RINGS

Refit the rings using the ring pliers .

The face of the sealing ring (2) marked TOP must be to the top .

Turn the gap of the ring (2) 180 degrees in relation to the gap of ring (1) .

The UFLEX type scraper ring (3) does not have a gap .

3 - LINERS/PISTONS ASSEMBLY

IMPERATIVE : it is necessary to assemble the liners/pistons before refitting the liners .

Oil the pistons .

Fit the ring collar [1] Moderately tighten .

Position the piston on the liner to obtain on fitting :

• the alignment of the liner/cylinder block marks
• the direction of the piston arrow on the timing side

Push the piston in the liner until the collar is freed .

Proceed in the same way for the other three assemblies .

Fit a new seal (4) to each liner taking care not to twist it .

Fit :

• connecting rod half shells

NOTE : FOR THE THICKNESSES OF THE BIG END SHELLS .

4 - REFITTING THE CRANKSHAFT

On the crankshaft, check the condition of the following parts :

• crankpins
• main journals
• taps
• cotter pin housings

Depending on engine type :

• refit the piston lubrication pipes (5)
• coat the bolts (6) with LOCTITE FREINEBLOC (or equivalent), tightening torque 1 da.Nm

Refit the grooved half shells (7) on the cylinder block .

Lubricate the crankshaft main bearings .

Fit :

• the crankshaft (8)
• the side stop thrust washers (9), grooved surface in contact with the crankshaft

NOTE : FOR THE THICKNESS OF THE STOP THRUST WASHERS .

Apply AUTO-JOINT OR sealing compound to the corners and ends (a) of main bearing no. 1 .

Place tool [2] on the cap of bearing no. 1 :

• the shim slide (12) must be in the extension of surface (11) of the bearing cap
• tighten the clamp (10)

Refit the side seals (15) in the groove of the main bearing cap, with the minimum protrusion at (b) .

Lubricate the two surfaces of the feelers (13) .

Place the feelers (13) on tool [2] above the heel (14) of the main bearing cap .

The side seals (15) must have a minimum protrusion of approximately 1 mm .

Engage the cap/side seal assembly in the cylinder block, by tilting the assembly .

Position the main bearing on the centralising bushes .

Tighten the 2 bolts (16) .

Remove the tool [2] sideways .

IMPERATIVE : the new side seals are supplied to the correct length and must not be cut, if the protrusion is too great, repeat the fitting operation .

Position the main bearing caps (17) with their half shells by positioning the lugs (18) towards the timing side .

IMPERATIVE : FOR THE IDENTIFICATION AND DETERMINATION OF THE BEARING HALF SHELLS .

XU5JP ENGINE XU7JB ENGINE XU7JP ENGINE XU7JP4 ENGINE

Tighten :

• the bolts (19) to 5.4 da.Nm
• the nuts (20) to 5.4 da.Nm
• the bolts (21) to 2.3 da.Nm

XU10J4R ENGINE

Tighten :

• the bolts (22) to 7 da.Nm

ALL MODELS

Fit the dial gauge [3] using tools [4] - [5 ] .

This end float should be between 0.07 and 0.27 mm .

Adjust the clearance by adjusting the thickness of the side stop thrust washers .

Fit a new oil seal (23) using the tool [6] .

Lubricate the lips of the seals .

Refit the seal by tapping with a mallet to the limit .

Remove the tool with a rotary movement .

Refit the 4 piston/connecting rod/liner assemblies (According to markings made during dismantling) .

Fit the liner retaining clamps [7] .

XU10J4R ENGINE

Lubricate the cylinders .

Respect the marks made on dismantling .

The piston arrow is directed towards the timing gear .

Retain the ring collar [1] in perfect contact with the block joint face and aligned in relation to the cylinder .

Insert the piston until the collar is free .

ALL MODELS

IMPERATIVE : always fit new connecting rod cap nuts .

NOTE : the connecting rods and their caps are matched and marked with coloured spots or numbers .

Lubricate the crank pins .

Refit the big end caps together with new half shells .

FOR THE IDENTIFICATION AND DETERMINATION OF THE BIG END HALF SHELLS .

Tighten the connecting rod cap nuts to the correct torque Using the tool [8] .

IMPERATIVE : FOR THE VARIOUS TIGHTENING TORQUES .

Refit the centralising pin (24) .

Fit :

• the cotter (25)
• the drive pinion (26) for the oil pump (27) on the crankshaft
• the oil pump (27) by placing the chain on the gears

Lift the oil pump (27) .

Insert the spacer (28) (Depending on engine type) .

Tighten the bolts (29), (30), (31) to 1.6 daN.m .

NOTE : bolt (29) is used to align the oil pump .

Fit a new lip seal (34) using the oil pump gear spacer (32) .

Coat the plate (33) with SILICONE CATEGORIE 2 sealing compound .

Tighten the bolts to 1.5 daN.m .

Depending on engine type :

• coat the spacer (35) on the surface in contact with the cylinder block with SILICONE CATEGORIE 2 sealing compound
• position the spacer on the cylinder block
• tighten the bolts (36) to 1 daN.m
• position the oil pump gear housing (37)
• tightening torque : 1 da.Nm

5 - REFITTING SUMP

Coat the cylinder block joint face with a thin even coat of LOCTITE AUTO-JOINT OR sealing compound .

The securing of the different oil sumps, depending on the engines, requires different bolts .

When refitting the sump, follow the relevant diagram and table .

F : At the gearbox end .

G : Oil filter cartridge side .

H : Timing gear end .

I : Exhaust side .

J : Reference A - XU10 .

J : Reference B - XU5 - XU7 .

5 - 1 - ALUMINIUM OIL SUMP

5 - 2 - STEEL SUMP