B1BJ0CK1 - 406D9 XU INJECTION

DISMANTLING - DISMANTLING ENGINE

1 - SPECIAL TOOLS

2 - DISMANTLING - DISMANTLING

WARNING : before any operations are carried out on the engine, it is recommended that it is secured on a DESVIL stand suitable for the engine .

IMPERATIVE : before any repair see : CRANKSHAFT PULLEY CHECK .

Remove :

• the ancillaries secured to the engine
• the inlet manifold
• the breather (1) with its tubes

Remove :

• the bracket for the oil gauge (2)
• the water inlet housing (3)
• the exhaust manifold (4)
• the casing (5)

Peg in the order :

• the crankshaft with the rod [2]
• the camshafts, using rods [1]

XU5JP ENGINE XU7JB ENGINE XU7JP ENGINE

Peg the camshaft using tool .

ALL MODELS

Lock the flywheel with the stop [4] .

WARNING : never slacken the bolt (6) with rod [2] in place (risk of damage) .

Slacken the bolt (6) .

Remove :

• the crankshaft pulley with the extractor [5]

IMPERATIVE : do not remove the crankshaft pulleys with vibration damper using the extractor [5] .

Remove :

• the bolts (7)
• the dynamic tensioner (8)

Remove (Depending on engine type) :

• the engine mounting (9)
• the covers (10) and (11)
• the thrust washer (12)

Slacken the bolt (13) .

XU5 INJECTION

Unscrew :

• the nuts (14)
• the nut (15)

Place the cam (16) horizontal using the square (17), the tensioner is then compressed .

ALL MODELS

Remove :

• the timing belt (18)
• the timing belt tensioner
• the camshaft pulley (19)
• the rod [3]

XU7JP4 ENGINE XU10J4R ENGINE

Remove :

• the 2 camshaft pulleys
• the setting rods [1]

ALL MODELS

Remove the coolant pump (20) .

Remove :

• the clutch mechanism
• the clutch plate
• the flywheel
• the tool [4]

Remove :

• the cylinder head covers (21)

XU7JP4 ENGINE XU10J4R ENGINE

IMPERATIVE : progressively slacken in a spiral sequence the bolts of each cylinder head cover (21), starting from the outside .

ALL MODELS

Starting at the outside and working in a spiral sequence progressively slacken the cylinder head bolts .

Remove :

• the cylinder head bolts
• the washers (depending on engine type)

Rock and free the cylinder head using levers [6] .

Remove :

• the cylinder head (22)
• the cylinder head gasket (23)

Remove the centralising dowels (24) .

Mark the position of the pistons in relation to the engine block .

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Secure the liner retaining clamps [7] using the 4 bolts (25) .

ALL MODELS

Remove :

• the oil sump and its seal
• the anti-foaming baffle (26) (depending on engine type)
• the thrust washer (27) (depending on engine type)
• the spacer (28) (depending on engine type)
• the seal carrier plate
• the pump/chain and oil pump pinion assembly
• the spacer (29) (depending on engine type)
• the oil pump centralising pin (30)

IMPERATIVE : mark the location of the big end caps and main bearings .

Remove :

• the big end caps (31)
• the bearing caps (32)
• the oil seal (33)

Recover the end float adjusting shims on the main bearing (no. 2) .

IMPERATIVE : mark the location of the main bearing half shells .

Remove :

• the crankshaft (34)
• the bearing half-shells
• the end float adjustment shims (35)

Remove :

• the piston lubrication pipes (depending on engine type)
• the piston/connecting rod assemblies

Refit the big end caps (31) .

XU5 INJECTION XU7 INJECTION

Mark the position of the liners in relation to the engine block .

Remove :

• the liner retaining clamps [7]
• the liners/connecting rods/pistons assemblies (36)

ALL MODELS

Depending on engine type :

• the gudgeon pin retaining rings

WARNING : some pistons are fitted with a boss (37); position the surface with the boss (37) upwards .

Remove the gudgeon pins using a press and tools [8], [9], [10] .

XU5 INJECTION XU7 INJECTION

IMPERATIVE : this operation involves the automatic replacement of the liners-pistons assemblies (pistons scrapped) .

XU10 INJECTION

IMPERATIVE : this operation makes replacement pistons necessary (cannot be re-used after removal) .

Tooling CITROEN .

Fit the piston on the base [11] .

Drive out the gudgeon pin using tool [10] .