Fixing, rebuilding 4 cylinder diesel engines XUD9TE

[GoceKU]

Over the years, fixing peugeot and citroen cars, i've replaced many engines or cylinder heads. 15 years ago parts and engines were more expensive but it was easy to find a low mileage engine in good condition. Now engine with million kilometers are more common, its come to the point it's almost impossible to find an engine ready to drop in a car. I've taken apart more then 20 engines some of them had nothing worth keeping but i've kept some of the good engine parts and i think its good time to sort thru the parts and put together 3-4 ready to install engines.

 

[GoceKU]

First engine i took apart was this 1,9td 1996 from a parts car 406, the story i got was that gas station attendant fill it with gasoline and he drove it till it started to smoke and make strange noises. He took it to a shop there they diagnose it bad turbocharger, he paid for a new turbo, but that did not fix the issue. The turbo looks new but i can see the aluminium housing is sandblasted, might be a refurbished turbo. Looking at this engine closer i could see its been apart before, the head bolts are over torqued and almost strriped at the head. Intake ports were very gunked up and then the cylinder head come off it was confirmed it has oversized pistons 83.720, MLS head gasket. I'll be taking the bottom end all the way apart but from what i could see the cylinders are good, i'll be measuring them are they to specs. From what i could see the cylinder head has some survive pre chamber cracks, i have few spare heads, lets hope they are in better shape.

 

[GoceKU]

Today i took apart this XUD7. This engine was left to me by the participants from the Europ raid. They drove it straight from athens greece (750 km) in few hours with speeds above 100km/h but apparently has a bad head or head gasket. From the looks the head is new or its been recently replaced the date on the head is 2020. There is also a sticker for the timing belt at 240k also back in 2021. The head bolts on this engine come off easily, not over torqued like the TE. With the head off i can tell it's been off recently and its warped, no visible cracks also the engine block is very warped it's obvious where it was blowing in between cylinders and torquing procedure wasn't done correctly. I'll have to have the heads and blocks i'm planning to use pressure tested before machine work gets done. Unfortunately the old guy that used to do my machine work died, so i'll need to take my parts to a new place next city over.

 

[GoceKU]

I've been asking around for a good machine shop to test couple of cylinder heads for me, but all the advice i got was they all just guess. Two of the fore mechanics who rebuild engines every day said they've had many instances where the shop garantie the head is good they refurbished it install it and creates more pressure than before. They explained that the machine shop never heat up the heads and test them with only a bar or two air pressure because there machines are so worn out they blow out. Also this particular cylinder heads are very difficult to be sure because they need cut out in the pressure plate for the pre chambers. With that in mind i decided to make me a specific plate so i can test them myself. Started with a 20mm plate a bit over sized, which i cut one side to shorten. I marked all the holes i plan to make except for the pre chambers those i'll make on a mill alongside cutting the cylinder bores and facing it on both sides that will take off lots of material and will end up with a thinner plate. I started to drill out the bulk of the bigger holes on my small drill but its overheating constantly. This will take a long time.

 

[pontiac428]

Goce, I have had questions about the Peugeot (and now Citroen, which the Germans pronounce Sit-hRoyen) small diesels.

I am one who believes the best engines for certain cars are swaps that were never offered from the factory. One popular swap is to install a VW 1.9 TDI in the Suzuki Jimny class trucks. I can't do this swap, because I know that the iron block of the VW diesel makes it a boat anchor at 400 lbs, against the original Suzi G13K's weight of 150 lbs.

My main question is what are the engine weights of the Peugeot and Citroen small diesels? Also, are Peugeots PS/KW power claims actually accurate? It seems to me like Peugeot puts the most powerful engines in the lightest cars!

 

[GoceKU]

Peugeot 1,9td is around 155 kg, 1,9d N/A is 150 kg. they makes around 90 hp with factory settings. The N/A is around 65 hp. That is a complete engine with fuel pump, water pump alternator, vacuum pump everything ready to run. Peugeot engine are completely mechanical one wire is needed to open the fuel solenoid and it will run forever, they can be tuned for more power with a 13mm wrench and a flat screwdriver, just tighten the wastegate on the turbo and let more fuel at the injection pump. I've dealt with VW 1.9TDI they are more modern design, they don't need glow plugs evry starting but they need an ECU, airflow metre, and a key imobilizator to run. For off roading if you are going in soft sand or mud the diesels don't have the RPM.

 

[GoceKU]

Also, are Peugeots PS/KW power claims actually accurate? It seems to me like Peugeot puts the most powerful engines in the lightest cars!

Older engines, 84-94 make more power than advertised also have less problems, no EGR, No catalytic converter. Newer, 94-04 also last forever but are smaguld with cheap injection pumps and emission equipment. Those cars need to be driven at open throttle every so often, they get carbon up. If the previous owner drove it at 1200 rpm they will feel slow as molasses, let my brother drove it for a week it will fly.

 

[GoceKU]

Some time ago i started making this part but every day job and other project pushed it back. Also my drill is very underpowered and overheats easy, so even when i had time it will over head and i'll move to another job. But little by little i drill all the holes and removed the big holes, drill and thread the bolt holes. At the end i use a hammer to smash them out, now i'll find time to take it to my friend's shop and get it machined on a mill. I need to make some more storage space, my XUD storage palce is overloaded.

 

[GoceKU]

Today i had little time to spare so i decided to start on getting things done on those engines. The xud7 cylinder head looked cleaner so i decided to take it apart first. First i took off the cam cover, and first ting i noticed the cam caps are wrong way around, and some one has marked the head like they are installed, the baskets look good but first one i took off i found this, someone did not have thin enough adjustment shims to adjust the valves so he grounded the shim. Seeing that i stopped, i was dealing with a someone else's hack work and that is never fun.

 

[GoceKU]

Last few weeks have been very busy for me, the start of a new school year and all but today i found me couple hours to spend in the big garage. With the big table clean, got me few egg cartons and started to lay down the cylinder heads on them. I found 5 heads some of them partly disassemble, the plan is to disassemble them, wash them and test them for cracks if fine continue and refurbish them. First i need to take them apart, they are incredibly dirty, just moving them got me incredibly dirty, and that small of used diesel oil. I usually keep the valve train in order as they come out to use them in the same order but that takes time and i'll try to work on them tomorrow.