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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Installation of a bent shaft and check of working gaps of radical bearings

Selection of inserts

Petrol engines (XU series)

On some engines installed on models of early years of release the top and lower inserts of radical bearings of identical thickness are applied.

On later models the working gap in radical bearings was considerably lowered for what began to use inserts of four various dimensional groups. The dimensional group of inserts is determined by the color marking applied on edge of each of them. At the same time thickness of an insert increases depending on color of marking in the order specified in the table given below. It is also necessary to draw the attention of the reader to that fact that the top inserts are used always the same thickness and gap size in bearings is defined by thickness (dimensional group) only of the lower inserts.

Engines 1580 and 1761 of cm 3

Color of marking

Thickness of an insert, mm

Standard
Repair

Top insert

   •  Yellow

1.856

2.006

Lower inserts

   •  Blue (Class A)

1.836

1.986

   •  Black (Class B)

1.848

1.998

   •  Green (Class C)

1.859

2.009

   •  Red (Class D)

1.870

2.020

Engines of 1998 cm 3

Color of marking

Thickness of an insert, mm

Standard
Repair

Top insert

   •  Yellow

1.847

Data are absent

Lower inserts

   •  Blue (Class A)

1.844

Data are absent

   •  Black (Class B)

1.857

Data are absent

   •  Green (Class C)

1.866

Data are absent

   •  Red (Class D)

1.877

Data are absent


On all engines of the XU series the top inserts of radical bearings easily differ from lower on the flute provided in them. Surface of the lower inserts always smooth. At the time of drawing up the present manual data on the repair sizes of inserts of radical bearings for engines of 1998 cm 3 were absent therefore at their selection it is necessary to address experts company service centers of the Citroyon company.

On the majority of models of the last years of release selection of replaceable inserts of radical bearings can be made on special marking. The marking containing information on diameters of beds of bearings is applied on the face surface of the block of cylinders. At the same time on a bent shaft the tags determining thickness of his necks are provided. If marking is absent, selection of inserts can be carried out only by measurement of working gaps in bearings (see below).

On the block of cylinders marking is applied on the left face wall from a flywheel / a driving disk. On a bent shaft - on a cheek of an extreme crank. On the basis of the analysis of the data included in marking selection of replaceable inserts of radical bearings is made.

And — the Reference used only on production
In — Designations

Both markings consist of two rows of data: the reference used on production and the code consisting of five letters. The first letter designates dimensional group of the first radical bearing (located from a flywheel / a driving disk), the second - the second, etc. is designated by the last letter which the tag in the form of an arrow follows dimensional group of the fifth bearing.


The card of the choice of inserts of the radical bearings used on petrol engines of the XU series

Selection of bearings is carried out as follows: Write out number of dimensional groups of a neck of a bent shaft and bed in the block for the first bearing and address data of the special picking card (see the illustration Card of the Choice of Inserts of Radical Bearings, used on petrol engines of the XU series). Pay attention that a horizontal number of figures/letters from above on the card defines dimensional groups of necks of a bent shaft, and vertical, - groups of beds in the block. Find a cell of crossing of the written-out numbers. The letter which is contained in this cell will designate the required dimensional group of the lower insert of the corresponding radical bearing which installation will provide the required working gap. For example, if the corresponding neck of a bent shaft is designated by number 6, and a bed in the block - a letter of N, it is necessary to complete this bearing with the lower insert with red marking (Class D).

Working in a similar manner, define dimensional groups of the lower inserts of the remained radical bearings.

It is the best of all to get replaceable inserts through company service centers of the Citroyon company.

When performing capital repairs of the engine on models of early years of release it is the best of all to select replaceable inserts from new, equipped with a color code change. However, it is admissible only if the corresponding modification of the lubrication system (with replacement of the piston of the reducing valve, a chain and driving asterisk of the oil pump is made. If modification of the lubrication system is not made, it is necessary to establish the lower inserts of the Class A (Blue marking). More detailed information can be obtained at car repair shops.

Diesel engines (XUD series)

On all diesel models radical bearings are completed with the top and lower inserts of identical thickness. The Citroyon company releases both that and others both the standard, and repair sizes.

Definition of a working gap of radical bearings

Petrol engines (XU series)

 PERFORMANCE ORDER

1. On models of early years of release pick up a set of new top inserts, then a set of new lower inserts with blue marking (see above) if such opportunity exists. On later models where the modified radical bearings are already installed, check of gaps in them can be checked with old inserts though the result cannot be considered more exhaustively exact (better also to take a new set).
2. Wipe backs of the picked-up inserts and their bed in the block of cylinders and covers of bearings.
3. Enclose inserts in the beds, having tracked that their uvulas entered gearing with reciprocal grooves in a body of blocks/covers. When checking old inserts track that they were established strictly on the former places. Try not to touch working surfaces of inserts. Pay attention that the flute is provided in working surfaces of the top inserts, - do not mix them with smooth lower.
4. Check of size of a working gap of bearings is made by one of the methods described below.
5. The first method more difficult in view of need of application of a micrometer and нутромера / Columbus, demands installation of covers of radical bearings (with the enclosed inserts) on the block. Tighten bolts of fastening of covers with the required effort (during check of gaps of bearings old bolts are used), then нутромером / Columbus measure the internal diameter of each of bearings. Now it is necessary to subtract diameters of the corresponding radical necks of a bent shaft from the received results, - the received results will show values of working gaps in bearings. Compare results of calculations to requirements of Specifications.
6. The second method (simpler and exact) means use of the special measuring Plastigage set (Citroyon No. OUT 30 4133 T). The size of a gap is determined by extent of flattening of pieces of the soft calibrated wire from set at its tightening between inserts of covers of radical bearings and necks of a shaft. Measurement of width of the flattened-out pieces of a wire is performed on the scale applied on set packing.
7. Enclose the top inserts of radical bearings in the beds in the block of cylinders, then carefully lay a bent shaft in the block. Do not use any lubricant! Necks of a shaft have to be absolutely pure and dry.
8. Cut five pieces of a wire, on length is slightly shorter than radical necks of a bent shaft and lay them along necks, parallel to an axis of the last.
9. Wipe working surfaces of the lower inserts in covers of bearings and grease them with a thin layer of a silicone compound for the purpose of prevention of sticking to them the calibrated wire. Install covers on the regular places in the engine (be verified with factory marking). Screw old fixing bolts and, watching to breaking integrity of the flattened-out wire pieces, tighten them with the required effort (see below in this section). Do not allow a provorachivaniye of a bent shaft after laying on it the calibrated wire.
10. Uncover, - again try not to destroy the flattened-out wire and not to turn a shaft.
11. On the scale applied on packing of the Plastigage set determine the size of a working gap of bearings by extent of flattening of the calibrated wire, you remember that on packing two scales can be put (inch and metric), - do not mix them. Compare results of measurements to requirements of Specifications.
12. If gap size significantly differs from demanded, check whether dirt or other foreign particles got under an insert back. Wipe backs of inserts and their bed and repeat check. At repeated negative result check compliance of inserts to diameters of necks of a bent shaft. If the calibrated wire is flattened out since one end inadmissibly it is more, than from another, the neck has conicity and is subject to a pro-point.
13. If results of measurements significantly differ from stipulated in Specifications, use the obtained data, and also data on thickness of inserts (see above) for definition of the required dimensional group of new inserts. Remember that it is always better to install working gaps in bearings closer to the lower bound of admissible range adjusted for wear.
14. If necessary pick up new inserts from other dimensional group and repeat check of working zazhor in bearings.
15. In conclusion, having made sure of compliance of sizes of a working gap of bearings to standard requirements, remove traces of the flattened-out wire from shaft necks, having carefully scratched out them a nail or edge of an old credit card.

Diesel engines (XUD series)

Check can be executed on old inserts though it will be more preferable to make it with a new set. Follow the instructions given above.

Final installation of a bent shaft

All engines (XU and XUD)

 PERFORMANCE ORDER

1. Accurately take a bent shaft from an engine case.

2. By means of couple of dabs of dense lubricant record the top half of persistent washers on both sides of a bed of the second radical bearing in the block of cylinders, - both washers have to be established by flutes of maslotok outside.

3. Enclose inserts of radical bearings in the beds in the block of cylinders and covers. At installation of new inserts track that from their surfaces the preserving lubricant was completely removed, - wash out inserts kerosene, then carefully wipe pure неворсящейся with rags. Plentifully grease inserts in an engine case with pure engine oil of the required grade.

4. Lay a bent shaft in the block of cylinders so that necks of the second and third cranks appeared in provisions of VMT, and the first and fourth, respectively, - NMT. According to instructions of the section Check of a Condition of a Bent Shaft, measure the size of its axial side play.

5. Oil motive the lower inserts in covers of bearings. Make sure of correctness of landing of uvulas of inserts in reciprocal deepenings in covers.

6. Establish covers of the second and fifth bearings on the regular places (deepenings under uvulas of inserts in beds of the block and covers have to appear on the one hand. Start fixture (nuts/bolts) and freely tighten it.

7. Grease with sealant the surface of the block interfaced to a cover of the 1st radical bearing, around openings under installation of sealing strips.

8. Get uvulas of sealing strips on pins in the basis of a cover of the first bearing and put strips in the flutes in a cover. Now it is necessary to prepare two thin metal plates (thickness less than 0.25 mm) for the purpose of fixing of sealing strips at installation of a cover.

9. The Citroyon company releases the special adaptation working like a clamp for this purpose, however, also couple of edges of the old measuring probe perfectly will approach (track that from their edges all agnails and teases capable to damage rubber of sealants were removed previously.

10. Oil the motive both parties of metal plates (if you use plates) and establish them on sealing strips. Install a cover of the first radical bearing on the engine and freely screw fixing bolts.

11. By means of flat-nose pliers take plates. Pull plates strictly horizontally.

12. Evenly tighten fixture of covers of radical bearings with the required effort, then a sharp knife cut protruding edges sealing covers of the first bearing so that they acted over the interfaced surface of the block approximately on 1 mm.



13. On models 1580 and 1761 of cm 3 screw side bolts of fastening of the central radical bearing, - one in a forward part of the block and one in back, - do not forget about sealing washers. Tighten both bolts with the required effort.
14. Establish a back epiploon of a bent shaft (see. The repair procedures which are not demanding extraction of the engine from the car - the petrol engines or Repair procedures which are not demanding extraction of the engine from the car - diesel engines).
15. Install on the places conrod and piston assemblies (see Installation of conrod and piston groups on the engine and check of working gaps of conrod bearings).
16. Establish a segment spline in a groove of pins of a bent shaft, then put on a pin the leading asterisk of the oil pump with the remote plug (if that is provided). Throw with a driving chain an asterisk.
17. Dry wipe the interfaced surfaces of the holder of a forward epiploon of a bent shaft and the block of cylinders. Measure depth of landing of an epiploon, then take it from the nest by means of the screw-driver with a flat sting.
18. Grease with suitable sealant the interfaced holder's surface. Make sure available on the places of the directing pins and put the holder on a pin of a bent shaft, having densely pressed it to the block. Tighten boats of fastening of the holder with the required effort.
19. Working according to the instructions stated in sections the Repair procedures which are not demanding extraction of the engine from the car - the petrol engines or Repair procedures which are not demanding extraction of the engine from the car - diesel engines, establish a new forward epiploon of a bent shaft.
20. Make sure of correctness of landing on asterisks of a driving chain of the oil pump, then install the oil pump and the pallet of a case (see. The repair procedures which are not demanding extraction of the engine from the car - the petrol engines or Repair procedures which are not demanding extraction of the engine from the car - diesel engines).
21. If removed, establish into place a head of cylinders (see. The repair procedures which are not demanding extraction of the engine from the car - the petrol engines or Repair procedures which are not demanding extraction of the engine from the car - diesel engines).


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