Citroën Xantia

since 1993 release

Repair and operation of the car



Citroën Xantia
+ Introduction
+ Operation manual
+ Routine maintenance
- Repair of the engine
   + The repair procedures which are not demanding extraction of the engine from the car - petrol engines
   + The repair procedures which are not demanding extraction of the engine from the car - diesel engines
   - Removal and capital repairs of the engine
      Capital repairs of the engine - the general information
      Removal of the power unit - methods and precautionary measures
      Removal, partition and installation of the power unit - model with RKPP
      Removal, partition and installation of the power unit - model with AT
      Order of dismantling of the engine by preparation it to carrying out capital repairs
      Dismantle of a head of cylinders
      Cleaning and check of a condition of a head of cylinders and components of the valvate mechanism
      Assembly of a head of cylinders
      Removal of conrod and piston assemblies
      Removal of a bent shaft
      Cleaning and check of a condition of the block of cylinders/case of the engine
      Check of a condition of conrod and piston assemblies
      Check of a condition of a bent shaft
      Check of a condition of inserts of radical and conrod bearings of a bent shaft
      Engine assembly order after performance of capital repairs
      Installation of piston rings
      Installation of a bent shaft and check of working gaps of radical bearings
      Installation of conrod and piston groups on the engine and check of working gaps of conrod bearings
      Initial start of the engine after completion of its capital repairs
+ Cooling systems, heating
+ Power supply system and release
+ Engine electric equipment
+ Coupling
+ Transmission
+ Power shafts
+ Uniform hydraulic system
+ Brake system
+ Running gear and steering
+ Body and finishing of salon
+ Onboard electric equipment
+ Schemes of electric equipment


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Cleaning and check of a condition of the block of cylinders/case of the engine

Cleaning

 PERFORMANCE ORDER

1. Remove all hinged units and components, and also electric sensors and switches from the block. For the fullest cleaning it is necessary to take release traffic jams, drill small openings in traffic jams, screw in them self-tapping screws and, the screws which grasped flat-nose pliers by heads, pull out traffic jams from the block.

2. On models with the aluminum block take sleeves of cylinders (see below the subsection "The Aluminium Block with "Wet" Sleeves", item 1).
3. At the corresponding complete set turn out a fixing bolt and take a distributing tube of masloraspylitel of cooling of pistons from the block.
4. Scratch out all traces of material of old laying from the interfaced surfaces of the block, and at the corresponding complete set, also from casting of covers of radical bearings. Try not to damage pro-masonry/sealing surfaces.
5. Take all caps of oil galleries (where they are provided). Caps are put very hardly and, perhaps, will demand drilling with the subsequent restoration of a carving a tap. At assembly of the engine replacement of caps is made without fail.
6. If the case is strongly polluted, performance of steam cleaning will be required.
7. After return of the block from cleaning it is necessary to clean all oil openings and galleries again. Wash out all internal channels of the block warm water. Continue washing until clear water does not begin to follow from openings. Carefully dry the block, then slightly oil its interfaced surfaces and mirrors of cylinders in order to avoid corrosion development. If there is an access to a source of compressed air, use it for acceleration of process of drying and a purge of openings, channels and galleries.

When using compressed air put on goggles!

8. If the case of the engine is polluted not too strongly, will be to wash out it hot soap water with application of a rigid brush enough. It is not necessary to try to save time for washing of the block - belong to this procedure with all responsibility. Regardless of the chosen cleaning method, as a result of its all oil openings and channels have to be absolutely pure, and the block - carefully dried up. In order to avoid corrosion development slightly oil mirrors of cylinders.

9. All carving openings in the block need to be "banished" the tap suitable by the size, having carefully removed corrosion products, old sealant and other deposits from carving rounds. Besides, such "pro-race" will help to restore the damaged carving. Whenever possible, blow openings compressed air, having removed from them shaving and garbage.

All traces of lubricant and solvent in order to avoid destruction of casting of the block with hydraulic pressure have to be completely removed from deaf openings when tightening bolts.

10. Grease with suitable sealant new caps of oil galleries and screw them in the openings in the block. Strongly tighten caps.
11. At the corresponding complete set establish to the place of a nozzle of masloraspylitel of cooling of pistons. Fix the distributing tube of sprays by bolts, having tightened the last with the required effort.
12. If you are not going to start immediately assembly of the engine, wrap the block in a pure plastic bag. Do not forget to take care also of protection of the interfaced surfaces and mirrors of cylinders against corrosion (see above).

Check of a state

Pig-iron block

 PERFORMANCE ORDER

1. Visually check casting of the block for existence of cracks and traces of corrosion. Check whether a thread in any of fixing openings is stripped. If there were suspicions on internal leak of cooling liquid, perhaps, it makes sense to address specialists of car service, having asked them to execute careful check of a condition of the block with use of the special equipment. In case of need make recovery repair or replace the block.
2. Check mirrors of cylinders for existence of scratches and zadir. At detection of such defects it is necessary to check a condition of the corresponding pistons. Points out existence of noticeable step wear in their top part considerable wear of cylinders.
3. For more exact assessment of degree of wear of cylinders it is necessary to perform measurement of their diameters in several points. Enter a nutromer into the first cylinder and perform measurement of its diameter in three various sections parallel to an axis of a bent shaft. One measurement is performed in the top part of the cylinder, directly under edge of a fillet of step wear, the second - in the central part of the cylinder and the third - at distance about 10 mm over the lower cut. All measurements are performed in the plane, a perpendicular axis of cylinders and parallel to an axis of a bent shaft.
4. Repeat measurements in former sections of cylinders, perpendicular to a shaft axis this time. Compare results of measurements to requirements of Specifications (in the absence of standard data, address for consultation experts company service center of the Citroyon company).
5. If any of results exceeds the limit of admissible range, cylinders are subject to a pro-point with the subsequent replacement of pistons on new, the corresponding repair size. The only alternative to a pro-point of cylinders is full replacement of the block complete with pistons.

The aluminum block with "wet" sleeves

 PERFORMANCE ORDER

1. Where it is required, remove clamps of sleeves, then by means of a drift from a firm tree beat out sleeves from the block. Having released sleeves from cylinders, turn the block sideways and take sleeves from cylinders manually. In process of extraction of sleeves, paste on their left walls (from transmission) adhesive tape strips on which inscribe number of the corresponding cylinder, including the first the next to a flywheel / to a driving disk at once.

2. Remove sealing rings from the bases of sleeves.

3. Check sleeves for existence of the deep scratches and zadir indicating excessive wear of their mirrors.
4. In the presence of near at hand measuring equipment, measure the internal diameter of a sleeve of the first cylinder in three sections parallel to an axis of a bent shaft (see above the subsection "Pig-iron Block", item 3).
5. Repeat measurements in the same sections, but perpendicular to a shaft axis. Compare results to requirements of Specifications.
6. Working in a similar manner, estimate degree of wear of the remained sleeves.
7. In case of wear of sleeves over an admissible limit, or with deep defects of their mirrors, it is necessary to get a replaceable set. In the absence of confidence in assessment of a condition of sleeves do not hesitate to ask for the help experts.
8. Replacement of sleeves of cylinders is made complete with pistons and piston rings. Sweep up that acquisition of sleeves in an individual order is not possible.
9. For the purpose of saving factory admissions sets of replaceable pistons and sleeves are divided into three dimensional groups. Identification of dimensional group of the piston is made by means of warranty marking (And, In or C) which is applied on their bottoms. Sleeves are marked by risks (from one to three) which are caused on from the top sponges. Sleeves from one risky it is used complete with group A pistons, with two - In and with three, respectively, - S. Dopuskayetsya installation in various cylinders of pistons and sleeves of different groups, however in each cylinder the sleeve without fail has to correspond on group to the piston.
10. Before installation of sleeves carefully wipe the surfaces of the block of cylinders interfaced to them. By means of a fine-grained emery paper to a zapoliruyta of an agnail and the tease, capable to lead to damage of new sealing rings. Dry wipe sleeves, then establish new sealing rings on their bases, previously having slightly greased the last.
11. At installation to the place of old sleeves you watch that they were put strictly in former cylinders and correctly were oriented in the block (on the pasted adhesive tape strips). Try when filling sleeves in cylinders not to damage sealing rings. Finally sleeves zastukivatsya in the block by the hammer through a drift from a firm tree. Blows have to be lungs and be put until the sleeve does not rest the landing coat hanger. Carefully wipe the acting surfaces of sleeves and slightly oil them in order to avoid corrosion development.
12. Having finished installation of sleeves, check the size of their vystupaniye from the block by means of the dial measuring instrument of plunger type (it is alternatively possible to use the measuring instrument of planeness and the probe of lezviyny type). Compare results of measurements to requirements of Specifications. The maximum difference of size of a vystupaniye between any two sleeves should not exceed the stipulated admissible value.
13. At installation of new sleeves their shift from the cylinder in the cylinder for the purpose of reduction in standard of control value is allowed (on a difference of sizes of a vystupaniye). Remember that the piston has to be rearranged together with a sleeve.
14. If it is not possible to achieve satisfactory result, ask for the help specialists of car service.


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