Refitting: engine — variant 2 Citroen Xsara I

Recommended tools

[1] belt tension measuring instrument with digital read out (SEEM) 4122-T

[2] adaptor for angular tightening 4069-T

[3] rocker pressure plate 4533-T.Z

[4] dial gauge support 5708-T.V2

[5a] dial gauge support rod 5708-T.V1

[5b] dial gauge support rod 5708-T.V3

[6] flywheel stop 4507-T.L

[7] fitting mandrel 4521-T.G (kit 4528-T)

[8] fitting mandrel 4507-T.F (kit 4528-T)

[9] flywheel locking tool 4507-T.A

[10] camshaft gear setting rod 4507-T.B

[11] camshaft gear stop 4533-T.Y

Refitting

Refit the class B (colour BLACK) half bearing shells on the cylinder block side

Bearings 1;3;5 = plain half bearing shells (cylinder block and bearing cap casing)

Bearings 2;4 = grooved half bearing shells (cylinder block and bearing cap casing)

Oil the bearing shells and the journals

Fit the crankshaft

Fit bearing caps 1-3-4 and 5, ensuring that they are paired with the correct half bearing shells

Draw up the bolts

Oil the pistons

Fit the piston ring compressor

Fit the pistons, ensuring that the markings made on dismantling are aligned

The arrow marked on the piston should point towards the valve timing end

Oil and fit the two crankshaft thrust bearings (1) to the bearing n°2 (cylinder block side)

Fit the bearing n°2 and lightly tighten the screws

Fit a dial gauge on the end of the crankshaft using the mountings [4], [5a] and [5b]

Push the crankshaft fully in one direction

Set the dial gauge to zero

Push the crankshaft fully in the opposite direction

There should be an endfloat of 0,07 to 0,27 mm

Adjust the endfloat by changing the thrust washers

Thickness of the thrust bearings

• 2,40 mm
• 2,50 mm
• 2,55 mm
• 2,60 mm

Oil and fit the big end shells

Fit the big end caps and tighten to 3,75 m.daN

Oil (threads and under the heads) and fit the main bearing bolts (2)

Using the tool [2] tighten the screws (2) to 2 m.daN + 50° ± 1°

Check that the crankshaft turns smoothly (no high spots)

Fit

• The oil pump centralising pin (3)
• The key to the crankshaft

Locate the whole assembly

• Oil pump
• Chain
• Drive gear

Tighten the oil pump fixing screws to 1 m.daN

Coat the seal surface (a) with a fine layer of AUTO JOINT OR (E10) silicone jointing compound

Fit the oil seal carrier plate (4)

Tighten the bolts to 1 daN.m

Coat the seal surface (b) with a fine layer of AUTO JOINT OR (E10) silicone jointing compound

Fit the plate (5)

Tighten the bolts to 1 daN.m

Coat the seal surface (c) with a fine layer of AUTO JOINT OR (E10) silicone jointing compound

Fit the sump (6)

Tighten the bolts to 1 daN.m

Refit the oil gallery plug (7) and tighten to 3 m.daN

Fit a new oil seal (8) to the fitting mandrel [7]

Fit the oil seal to the plate (5)

Fit the flywheel

Coat the flywheel screw threads with Loctite FRENETANCH E3

Fit the stop [6]

Tighten the bolts to 6,5 daN.m

Remove the stop [6]

Fit the oil gallery plug (9) and tighten to 6,5 m.daN

Fit a new oil seal (10) to the fitting mandrel [8]

Fit the oil seal against its shoulder by means of the bolt (11)

Check that the cotter (12) is fitted

Fit the spacer (13)

Apply a fine layer of AUTO JOINT OR (E10) compound to the spacer/crankshaft connection and the key

Fit the timing gear (14)

Refit the screw (11) and its washer

Tighten the bolt (11) to 10 daN.m

Remove the stop [6]

Refit the coolant pump (15) using a new seal

Tighten the bolts to 1,75 daN.m

Turn the crankshaft and peg it in the Top Dead Centre position with the tool [9]

Fit the centralising pins (16)

Fit a new cylinder head gasket (notches on clutch side and markings uppermost)

Fit the camshaft gear (17)

Refit the fixing screw (18) and tighten by hand

Refit the cylinder head

Peg the camshaft with the peg [10]

Brush the threads of the cylinder head bolts

Apply thread locking product MOLYCOTE G RAPID PLUS (G1) to the threads and under the heads of the screws

Oil the cams and valve rocker pads

Refit

• The rocker shaft (19)
• The cylinder head bolts (20)

Cylinder head tightening

In three stages, bolt by bolt, in the order shown

• Pre-tighten to 2 daNm
• 1st angular tightening to 120° using the tool [2]
• 2nd tightening to 120°

Refitting timing gear

Refit the roller tensioner (21)

Fit the nut (22) and tighten it by hand (tensioner in minimum position)

Fit a new timing belt

Fit the belt, the right way round, with run (d) taut, in the following order

• Crankshaft
• Camshaft
• Coolant pump
• Roller tensioner

Turn the roller tensioner anti-clockwise to tension the belt (d) lightly

Tighten the nut (22)

Remove the timing tools [9] [10]

Turn the crankshaft 4 turns in the normal direction of rotation

Fit the stop [11]

Tighten the bolt (23) to 8 daN.m

Remove the stop [11]

Adjust the valve rockers

• Inlet valve = 0,20 mm
• Exhaust valve = 0,40 mm

Bring the engine to the pegging position and engage the flywheel peg [9] and the camshaft peg [10]

Position the rocker plate [3] ensuring that it is fitted in the correct direction with regard to the valve gear

Tighten all the bolts (e) and ensure that all the cams are free without the valves being in contact with the pistons

Fit the belt tension measuring instrument [1] in place

Unscrew nut (22)

Turn the roller tensioner (21) anti-clockwise to display 44 SEEM units

Tighten the nut (22)

Remove tools [3], [10], [9]and [1]

Turn the crankshaft 2 turns in the normal direction of rotation

Without turning backwards, peg the flywheel

Ensure that the timing has been set correctly (it is possible to peg the camshaft pulley)

If this is not the case, repeat the belt tensioning operation

Replace the rocker contact plate [3] and ensure that all the cams are free

Fit the belt tension measuring instrument [1] in place

The tension value should be between 29 and 33 SEEM units

If this is not the case, repeat the belt tensioning operation

Remove tools [3], [10], [9]and [1]

Refit the coolant hose union (24) with a new seal

Tighten to 1 daN.m

Refit the engine mounting (25)

Tighten to 5 daN.m

Fit the tool [6]

Refit

• The disc (26) (damper hub on mechanism side)
• The clutch mechanism (27)

Tighten the mechanism to 1,5 m.daN

Remove the stop [6]

Fit a new thermostat in the coolant housing

Check that the sealing joint is present

Coat the sealing faces of the two housings with a fine layer of AUTO JOINT OR E10 silicone sealing compound

Refit

• The thermostat (28)
• The distributor drive locking housing (29)

Tighten the bolts to 1 daN.m

Refit the timing plate (30)

Tighten to 1 daN.m

Ensure that the fuel rail components are in the right position and that the injector O-ring seals are in good condition

Fit the fuel rail (31)

Fit the new rubber seals to the inlet manifold

Tighten

• The nuts (32) to 1 m.daN
• The bolts (33) to 1 da.Nm

Ensure that the fuel rail/manifold connection is in the right position

Tighten to 1 daN.m

Reconnect the fuel pressure regulator hose

Refit

• A new oil filter cartridge
• The oil pressure switch (34)

Tighten to 2,75 daN.m

Refit

• The dipstick tube (35) (use FORMETANCH E4 adhesive to seal it in the cylinder block)
• The exhaust manifold (36) (equipped with a new seal)

Tighten to 1,5 daN.m

Refit the heat shield (37)

Tighten to 1 daN.m

Refit the timing cover sections

Tighten the bolts to 0,5 daN.m

Refit

• The deflector plate (38)
• The 2 spacers (39)
• The cylinder head cover (40) (equipped with a new seal)

Fit the new seal washers beneath the nuts

Tighten to 0,5 daN.m

Connect the sparking plug high tension leads

Clip the high tension leads wires to their mounting on the cylinder head cover