Refitting: engine (2.1 TD) Citroen Xantia I facelift

Tooling

[1] 4060-T (-).0117 AH dial gauge support

[2] dial gauge support

[3] 2437-T (-).1504 dial gauge

[4] 7014-T.F (-).0153 A bearing no. 1 side seals fitting tool

[5] 4069-T FACOM D360 adaptor for angular tightening

[6] 7016-T.Q (-).0153 PZ crankshaft seal fitting tool (flywheel side)

[7] 750-T type 750 TB clip for fitting the piston rings on the engine

[8] 7004-T.B (-).0153 E crankshaft seal fitting tool (timing side)

[9] 6012-T FACOM D86 toothed sector for locking the flywheel

[10] 7011-T (-).0216 C clutch friction centring rod; XUD11 A engine

[11] 4062-T.B (-).0214 clutch friction centring rod; XUD11 ATE/BTE engines

[12] 1754-T.bis (-).0110 H dial gauge support

[13] 7014-T.J (-).0153 N flywheel setting rod

[14] 6016-T (-).0132 AA toothed belt pinion locking tool

LUCAS DIESEL equipment

[15] setting rod

[16] dial gauge support

BOSCH equipment

[17] dial gauge

[18] dial gauge support

[19] extension

[20] fuel pump setting rod EPIC

Refitting

Piston rings

Refit the piston rings (as shown in the diagram above)

Assembling the connecting rods/pistons

Refit

• The circlip (4)
• The connecting rod (3)
• The shaft (2)
• The circlip (1)

Preparing the cylinder block

Refit

• The piston base jets (5)
• The grooved bearing shells (8)
• The lateral shims (6) and (7) (lubricating grooves "f" on the crankshaft side)

Adjusting the crankshaft endfloat

Fit the crankshaft

Position

• The dial gauge support [1]
• The dial gauge support [2]
• The dial gauge [3]

Push the crankshaft back and forth in the cylinder block

Set the dial gauge to zero

Push the crankshaft back and forth, on the opposite side, in the cylinder block

There should be a 0,12 to 0,32 mm endfloat

Crankshaft bearing caps

2.5.1 crankshaft bearing caps (bearing N° 2, 3, 4, 5)

Oil

• The crankshaft seats "g"
• The bearing shells (14)

Refit

• The bearing shells (14)
• The bearing caps (9), (10), (11) and (12)
• The lateral shim (13) (bearing N° 2)
• The bolts (without tightening)

Bearing cap (bearing N° 1)

Apply sealing compound (E4) in the corners and to extremities "h" of bearing N°1

Put tool [4] into place on the cap of bearing N°1 (15)

• The shim slide must be in the extension of surface of the bearing cap (15)
• Tighten the clamp (4a)

Place the bearing shell (16) on the bearing cap (15)

Place the side seals (17) in the groove of the bearing cap with the minimum of projection at "j"

Lubricate the two surfaces of the feelers (4b)

Place foils (4b) in position on tool [4], above the heel (18) of bearing cap (15)

The side seals (17) must have a minimum protrusion of approximately 1 mm

Tilt the bearing cap / lateral seal assembly to engage it in the cylinder block

Position the bearing cap (15) on the centring rings

Screw in the two bearing cap screws (15)

Remove the tool [4] sideways

2.5.2 tightening the bearing caps (9), (10), (11), (12), (15)

Tighten the screws, observing the order and the tightening torque

• XUD11 engine: tightening to 7 m.daN
• XUD11 ATE/BTE engines: pre-tighten to 1,5 m.daN, then carry out an angular tightening of 60 °; using tool [5]

Rear bearing shell seal ring

Fit the oil seal onto the tool [6]

Refit the ring seal; using a mallet

Remove the tool [6]

Connecting rod/piston assemblies

Check that the piston ring gaps "a, b, c" are facing in the right direction

Place ring collar [7]

Fit the half bearing shells (20) on the connecting rods (19)

Oil

• The cylinders (21)
• The half bearing shells (20)

Refit the connecting rod/piston assemblies

Big end caps

Equip the connecting rod caps with bearing shells

Position the conrod caps

Fit the nuts (22). pre-tighten to 2 m.daN, then carry out an angular tightening of 70 °; using tool [5]

Oil pump

Refit simultaneously

• The cotter (standard or after-sales according to RPO N°)
• The pinion (23)
• The chain (24)
• The oil pump (25)
• The securing bolts (26); tighten to 1,8 daN.m

Reference

• "l": = 65 mm long
• "m": = 70 mm long
• "n": = 80 mm long

Front sealing panel - sealing ring

Apply a strip of "E4" to the sealing panel (28)

Refit

• The sealing panel (28)
• The bolts (29) (length: 18 mm)
• The bolts (27) (length: 35 mm)

Tighten the bolts (27) and (29) to 1,2 m.daN

Crankshaft seal ring (timing side)

Refit the ring seal; using tool [8]

Remove the tool [8]

Lower cover

2.12.1 steel sump

Refit

• The new seal
• The sump (32)
• The bolts (30) (length: 20 mm)
• The bolts (31) (length: 16 mm)
• The bolts (33) (BTR) (length: 20 mm)

Tighten the bolts (30), (31) and (33) to 1,6 m.daN

2.12.2 aluminium sump

Apply a strip of sealant "E10" around the edge of the cylinder block

Refit

• The sump (37)
• The bolts (35) (length: 22 mm)
• The bolts (36) (length: 40 mm)
• The (34) bolt (length: 20 mm)

Tighten the bolts (35), (36) and (34) to 1,6 m.daN

Engine flywheel

2.13.1 manual gearbox

Refit

• The flywheel (38)
• The bolts (39)
• The stop [9]

Tighten the bolts (39) to 4,8 daN.m

2.13.2 automatic gearbox

Refit

• The flywheel (41)
• The shim
• Torque converter drive plate (40)
• The spacer (42)
• The bolts (43)
• The stop [9]

Tighten the bolts (43) to 4,8 daN.m

Remove the stop [9]

Clutch (manual gearbox)

Refit

• The clutch disc
• The clutch mechanism (45)
• The bolts (44)

Centre the clutch disc using the tool

• [10]: XUD11A engine
• [11]: XUD11ATE/BTE engine

Tighten the bolts (44)

• XUD11A engine: 1,3 daNm
• XUD11ATE/BTE engine: 2 daNm

Remove the stop [9]

Heat exchanger - oil filter

Coat the threading of the screw (46) with the product (E6) (cylinder block side)

Refit the heat exchanger (47)

Tighten the bolt (46) to 5,8 daN.m

Refit

• The oil filter (49)
• The switch (48) (new seal)

Filler tube and pipes

Refit

• The pick-up unit (50)
• The hoses (51) and (52)

Fuel pump support

Refit

• The bracket (53)
• The bolts (54). tighten to 2 daN.m

Fuel pump

2.18.1 mechanical fuel pump (LUCAS DIESEL equipment)

Refit

• The fuel pump (57)
• The washers (56)
• The nuts (55) (without tightening)
• Rear fixing (58) (without tightening)

2.18.2 mechanical fuel pump (BOSCH equipment)

Refit

• The fuel pump (59)
• The washers (60)
• The nuts (61) (without tightening)
• Rear fixing (62) (without tightening)

2.18.3 electronic fuel pump (LUCAS DIESEL equipment)

Refit

• The fuel pump (66)
• The washers (64)
• The nuts (63) (without tightening)
• Rear fixing (65) (without tightening)

Fuel pump pulley

Refit

• The cotter
• The pulley (68)
• The nut (67)

Immobilise the fuel pump pulley (68); using tool [14]

Tighten the nut (67) to 5 m.daN

Fixed roller and crankshaft pinion

Refit

• The cotter (69)
• The crankshaft gear (70)
• The roller (71)
• The (72) bolt; tighten to 3,7 daN.m

Water inlet housing

2.21.1 naturally aspirated engine

Refit

• The seal (73) (new)
• Coolant inlet housing (74)
• The bolts (75); tighten to 1,8 daN.m
• The thermostat (76)
• The unit (77)
• The bolts (78); tighten to 2,3 daN.m

2.21.2 turbocharged engine

Refit to the coolant inlet housing (82)

• The thermostat (81)
• The unit (79)
• The bolts (80)

Apply a strip "p" of "E10" to the back of the coolant inlet housing

Refit

• The unit (84)
• The bolts (83); tighten to 1,8 daN.m
• The bolts (85); tighten to 1,8 daN.m

Coolant pump

2.22.1 naturally aspirated engine

Refit

• The seal (new)
• The coolant pump (86)
• The bolts (87); tighten to 1,2 daN.m

2.22.2 turbocharged engine

Refit

• The seal (new)
• The coolant pump (88)
• The bolts (89); tighten to 1 daN.m

Piston protrusion

Fit dial gauge support [12] to the cylinder block

Secure dial gauge [3] to support [12]

Set the dial gauge to zero at "r"

Record the height difference at "q"

Cylinder head

Cylinder head gasket identification

• Naturally aspirated engine: marking "s" (green)
• Turbocharged engine: marking "s" (red)

Lubricate the threads and underside of heads of the bolts

Peg the camshaft with an 8 x 125 bolt

Refit

• The cylinder head
• The washers
• The bolts

Cylinder head tightening

Proceed bolt by bolt in the order shown

• Order of tightening: 1 to 10
• Loosening sequence: 10 to 1

Naturally aspirated engine

Bolt without guide boss, bolt with guide boss

• Tightening to 7 m.daN
• Tighten by an angle of 150 ° with tool [5]

Turbocharged engine

Bolt without guide boss

• Pre-tighten to 7 m.daN, then carry out an angular tightening of 150 °; using tool [5]
• Engine's temperature warm up
• Leave the engine to cool for a minimum of 3 hr 30
• Slacken the cylinder head bolts 90°; using tool [5]
• Angular tightening of 150°; using tool [5]

Bolt with guide boss

• Tightening to 6 m.daN
• Tighten by an angle of 180 ° with tool [5]

Timing belt

Peg the flywheel with tool [13]

Peg

• The camshaft; using the 1 screws 8 x 125 (t)
• The fuel pump; using the 2 screws 8 x 125 (u)

Position the timing belt, span "v" correctly tightened, in the following order

• The crankshaft gear (70)
• The tensioning roller 71
• The fuel pump pulley (68)
• The camshaft pulley (92)
• The coolant pump gear (96)
• The roller tensioner (91)

Unscrew

• The (94) bolt
• The locknut (93)
• The nut (97)

Release the eccentric (95)

Remove

• The timing pegs (bolt "t", "u")
• The tool [13]

Turn the crankshaft 2 turn(s) in the direction of running

Tighten

• The (94) bolt
• The locknut (93)
• The nut (97)

Turn the crankshaft 2 turn(s) in the direction of running

Refit

• The timing pegs (bolt "t", "u")
• The tool [13]

Remove

• The timing pegs (bolt "t", "u")
• The tool [13]

Setting the fuel pump

2.27.1 mechanical fuel pump (LUCAS DIESEL equipment)

Tilt the fuel pump towards the exterior of the engine

Remove the plug (98)

Position

• The peg [13]
• The peg [15]
• The dial gauge support [16]
• The dial gauge [3]

Press on peg [15]

Set the dial gauge [3] to 0

Release peg [15]

Tilt the pump towards the engine until the reading on the dial gauge [3] is the same as that recorded on the load lever (99) (± 0,02)

Tighten

• The nuts (55) to 1,8 m.daN
• The rear fixing (58) to 2 m.daN

Remove the peg [13]

Turn the crankshaft 2 turn(s) in the direction of running

Refit the peg [13]

Check that the reading on the dial gauge [3] is still the same as that on the load lever (99) (± 0,02)

Remove

• The dial gauge [3]
• The dial gauge support [16]
• The peg [15]
• The peg [13]

Refit the plug (98) (tighten moderately)

2.27.2 mechanical fuel pump (BOSCH equipment)

Position the fuel pump at mid-slots

Remove the plug (100)

Position setting rod [13]

Attach the extension [19] to the dial gauge [17]

Place the assembly into the mounting [18]

Fit the tool [18] instead of and in place of the plug (100)

Use the knurled fitting [18] to tighten the dial gauge [17]

Search for the bottom dead centre of the fuel pump piston by tilting the fuel pump towards the exterior of the engine

Remove the peg [13]

Turn the crankshaft in the reverse direction of rotation to find the bottom dead centre of the fuel pump piston

Set the dial gauge [17] to 0

Turn the crankshaft in the normal direction of rotation so that it can be pegged

Refit the peg [13]

Tilt the fuel pump towards the engine to obtain the setting value on the dial gauge [17] (see table below)

Tighten

• The nuts (61) to 1,8 m.daN
• The rear fixing (62) to 2 m.daN

Remove the peg [13]

Turn the crankshaft 2 turn(s) in the direction of running

Refit the peg [13]

Check that the reading on the dial gauge [17] complies with the timing value

Remove

• The peg [13]
• The tool [18]
• Tools [17] and [19]

Refit the plug (103)

2.27.2 electronic fuel pump (LUCAS DIESEL equipment)

Peg

• The flywheel; using tool [13]
• The camshaft; using the 1 screws 8 x 125
• The fuel pump (66); using the 2 screws 8 x 125

Tilt the fuel pump (66) towards the exterior of the engine

Remove the plug (101)

Insert the peg [20] into the hole "w"

Turn the fuel pump (66) towards the interior of the engine; press tool [20] untill it subsides

Tighten

• The nuts (63) to 2 m.daN
• The rear fixing (65) to 2 m.daN

Remove

• The tool [20]
• The pump pulley locating bolts
• The peg [13]

Refit the plug (104); tighten to 0,5 daN.m

Cold fast idle cable

2.28.1 mechanical fuel pump (LUCAS DIESEL equipment)

Refit

• The cable (104)
• The cable clamp 105

Push the lever (102) against its stop

Tighten the cable-clamp (105)

Finish tightening using the knurled screw (103)

2.28.2 mechanical fuel pump (BOSCH equipment)

Refit

• The cable (110)
• The cable clamp 107

Push the lever (108) against the stop (109)

Tighten the cable-clamp (107)

Finish tightening using the knurled screw (106)

Cylinder head cover

Refit

• The cylinder head cover (111)
• The bolts (112); tighten in a spiral sequence to 0,8 m.daN (from the centre outwards)

Fuel high pressure pipes

Refit the high pressure fuel pipes

Tighten to 2,5 daN.m

• The unions on the fuel pump
• The unions on the diesel injectors

Engine degassing and cooling system

Refit

• The coolant hose (118)
• The clip (117)
• The coolant hose (113)
• The clip (114)
• The degassing hose (116)
• The clip (115)

Refit

• The tube (119)
• The tube (120)

Refit

• The bracket (122) (on the water inlet housing)
• The (121) bolt; tighten to 1 daN.m

Turbocharger lubricating pipe

Refit the pipe (123)

Tighten

• The union (125) to 3 m.daN (on the engine)
• The union (124) to 2 m.daN (on the turbocharger)

RH engine support

Refit

• The right-hand engine mounting (126)
• The bolts (127); tighten to 2,7 daN.m

Timing covers

Refit

• The sump (131)
• The top cover (128)
• The lateral casing (129)

Lock the upper fixing by 1/4 of a turn

Tighten

• The bolts (130) to 1,8 da.Nm
• The screw (132) to 1 m.daN

Accessories drive pulley

Refit

• The stop [9]
• The pulley (133)
• The washer (132)
• The (131) bolt (apply the product (E6) to the threading); pre-tighten to 7 m.daN, then carry out an angular tightening of 60 °; using tool [5]

Remove the stop [9]

Intake pipes

Refit

• The seal
• The air inlet manifold (134)
• The bolts (135); tighten to 2,3 daN.m

Air inlet manifold

2.37.1 plastic air inlet manifold

Refit

• The inlet manifold (137)
• The bolts (136); tighten to 1 daN.m
• The bolts (138); tighten to 0,5 daN.m

2.37.2 aluminium air inlet manifold

Refit

• The inlet manifold (140)
• The bolts (141); tighten to 1,5 daN.m
• The bolts (139); tighten to 1 daN.m

EGR pipe (according to equipment)

Refit

• The EGR pipe (143)
• The clip (142)
• The clip (144)