Goce Posted August 23, 2023 Report Share Posted August 23, 2023 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. Quote Link to comment Share on other sites More sharing options...
Goce Posted August 23, 2023 Author Report Share Posted August 23, 2023 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. Quote Link to comment Share on other sites More sharing options...
SRDT Posted August 24, 2023 Report Share Posted August 24, 2023 It's not just prechambers, the head itself is also craked. Some say that the tweaks made by PSA on later engines to keep them emission compliant with 90hp also reduced durability. At least it is sure that R&D was much more focused on the next direct injection head for the HDI as emission rules and market trends made direct injection kind of mandatory for new turbo engines. Quote Link to comment Share on other sites More sharing options...
Goce Posted August 24, 2023 Author Report Share Posted August 24, 2023 All pistons have old marks from intake valves also found pieces of an old timing belt. From what i could figure someone did not change the timing belt long time ago and crash the valves, probably the camshaft and camcaps. I'm not sure is there a way to distinguish camshafts from a turbo or N/A engines. Quote Link to comment Share on other sites More sharing options...
SRDT Posted August 24, 2023 Report Share Posted August 24, 2023 Unless it's a very old camshaft or one from a XUD7T/XUD9SD it should be the same cam profile for both N/A and turbo, even the DW8 was no exception. The other variation is on the end of the camshaft: either machined for pulley(s) or direct drive for the vacuum pump. Quote Link to comment Share on other sites More sharing options...
Goce Posted August 25, 2023 Author Report Share Posted August 25, 2023 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. Quote Link to comment Share on other sites More sharing options...
Goce Posted August 28, 2023 Author Report Share Posted August 28, 2023 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. Quote Link to comment Share on other sites More sharing options...
Goce Posted September 5, 2023 Author Report Share Posted September 5, 2023 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. Quote Link to comment Share on other sites More sharing options...
Goce Posted September 9, 2023 Author Report Share Posted September 9, 2023 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. Quote Link to comment Share on other sites More sharing options...
Goce Posted September 16, 2023 Author Report Share Posted September 16, 2023 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. Quote Link to comment Share on other sites More sharing options...
SRDT Posted September 16, 2023 Report Share Posted September 16, 2023 Valves evolved a few times along the years so it's better not to mix them blindly. Quote Link to comment Share on other sites More sharing options...
Goce Posted September 17, 2023 Author Report Share Posted September 17, 2023 Today i took apart all 5 cylinder heads. All parts are organised i had couple of surprises. There is lots of corrosion in two of the heads, one has broken camshaft cap, almost all seem to had some work done on them. Many have evidence of replacement valves and cam caps, this engines when they brake the timing belt from not changing the belt on its intervals they bent valve or two but also brake the camshaft and the camshaft caps. The most surprising was the XUD7 head i took of the french engine it has green dual spring on the valves and there is not valve seals, the valve guide is not even machined to aspect valve seat. In so many XUD engines i've work on i've never seen that, i'm not sure why are there dual valve spring or why it doesn't have valve seals, there is no evidence of it burning oil also. Quote Link to comment Share on other sites More sharing options...
SRDT Posted September 18, 2023 Report Share Posted September 18, 2023 There was no valve seals on old engines, in France the XUD7T started using them around mid-92 (XUD7T/L) and the older engines with seals are the "clean" ones with EGR and cat. Dual springs means the engine was made before late 1988 (around october for XUD9 and decemeber for XUD7). Quote Link to comment Share on other sites More sharing options...
Goce Posted September 18, 2023 Author Report Share Posted September 18, 2023 The 205 that the engine come out of was 1994, but it was obvious that cylinder head was changed, it was cleaner. Also i've seen 21 date year cast on the head, perhaps someone use the valve train of an older head but that doesn't explain the valve guides. The casting code is same as all the others N/A heads i have P08, the turbo heads are P06 casting. Very strange, perhaps i should measure the cylinders to check if someone has put XUD9 pistons in it. Quote Link to comment Share on other sites More sharing options...
Goce Posted September 20, 2023 Author Report Share Posted September 20, 2023 With two full time jobs, i've been very busy but i managed to find time to pressure wash one cylinder head, i somehow picked the dirtiest one. This one is of a 92 XUD9 that come out of a peugeot 309 engine code DJZ. The condition is decent, it has some corrosion in the coolant passages also couple of broken bolts, but the camshaft journals are in good shape and no visible cracks. Cleaning the head with degreaser made a mess of my driveway also i looked like a dalmatian. I'll try to wash more parts at once next time. Quote Link to comment Share on other sites More sharing options...
Goce Posted September 22, 2023 Author Report Share Posted September 22, 2023 Today i got one more cylinder head clean up. I wanted to clean up more but i did not have time. This time around i clean up one of the cleaner ones, this head was clean on the outside but inside i that lots of oil gunk. This is the one without oil seals. Most of the carbon come out of the intake and exhaust ports but there's still some to come out, i'll use a wire brush after the resurfice. This time around i used compressed air and oil to protect the steel valve seats and bolts from rust. Quote Link to comment Share on other sites More sharing options...
Goce Posted September 24, 2023 Author Report Share Posted September 24, 2023 Today i spent an entire evening pressure washing the remaining 3 cylinder heads, i also washed 3 of the roker covers. You can see in the pictures it got dark on me during the washing, I spent lot of time with the oven degreaser and a brush scrubbing. No real suprases only the know good turbo head has lots of corrosion from not running coolant. Quote Link to comment Share on other sites More sharing options...
Goce Posted October 24, 2023 Author Report Share Posted October 24, 2023 Well this project has slow down but not stall, i've been busy but i found time to make a shelf and store the heads and head parts. More to come. Quote Link to comment Share on other sites More sharing options...
Goce Posted October 31, 2023 Author Report Share Posted October 31, 2023 Last few days i've been calling around machine shops to get the cylinder heads and engine blocks resurfaced. No machine shop in my city is still working the corona virus closed them all, the closes is in the main city and they are booked till new year also there price seems really high. So after seeing my options i consider buying a big milling machine but decided i don't have the space to store it. So i call a friend who has one and we determent i need to take the oil pan, oil pump and clean the flange. I did that loaded it in my lada niva and took it to him, it's heavy so i regretted not taking the crank out. This is the XUD7 engine block and with 0,04mm clean up but we made one more pass to get better surface finish and took a total off 0,08mm, i was expecting to have a bent block because i was told it overheated badly. I'll have to clean out this engine block very well now to get all the milling dust off. The surface finish we achieve is almost mirror finish much better then the factory finish. Quote Link to comment Share on other sites More sharing options...
Goce Posted November 3, 2023 Author Report Share Posted November 3, 2023 Last few days i've been asking around at machine shops to get the cylinder heads resurfaced. The peugeot cylinder heads have around 22 degrees at the camshaft flange in other words mounting them to a mill is difficult without a bunch of set up. A friend who is doing resuficing on a mill actually ask me how to make a fixture to hold the heads straight. After looking thru his and my scrap piles we found a peugeot cylinder head that was beyond repair. So i took it home, washed it, knock out all the valve guides, frizz plugs and any other steel to make it lighter thinking i have to cut it. Lay it in a table and drilled out the threaded holes so the studs from a good head can lock in them. Grab a good head from the shelf and it slotted in and is perfectly level. The plan is to get the jig head resurfaced first to keep the heads level. It may look weird but in my mind this a good solid piece of aluminium that is already at the perfect angle and height. Quote Link to comment Share on other sites More sharing options...
SRDT Posted November 3, 2023 Report Share Posted November 3, 2023 It's a good locating surface, if the top is also wraped you shouldn't use the head anyway. Quote Link to comment Share on other sites More sharing options...
Goce Posted November 4, 2023 Author Report Share Posted November 4, 2023 The recently resurfaced engine block got clean out and reassembled. Today i started with taking the oil pump apart, it is in excellent shape, clean out everything put it together, its the original with 1/4 million km on it from 1994. Then i clean out the oil pan again no real sludge just old gasket to clean out, decided to use only silicone no gasket. Then i oiled the cylinders and heads surfaced and dropped few pieces of paper to protect it. Then i lowered the complete block from the table to wait till its head gets done. Next i lifted two engine blocks one turbo other N/A i'll be taking them completely apart, and getting them ready to go to get the cylinders hone and resurfaced. The difference in the block casting is very obvious which one is turbo. Quote Link to comment Share on other sites More sharing options...
Goce Posted November 18, 2023 Author Report Share Posted November 18, 2023 Today i got back to working on this project. I have two lower ends to take apart, one on the left is N/A, the one on the right is Turbo. Everything is different even the block casting is different. Started on the N/A block, took the oil pan, there is some slage but not too much. Took off the oil pump, front cover chan drive then i moved to taking out the pistons. The cylinders have a good size rige at the top so i used my cordless drill and a hone to knock it down to get the pistons out without damage. I've order a cilinder mesuring bore gauge and i'll see if this block is in usable spacs or it needs to get slives. At this point i stopped i'll washed all the parts before taking apart the other block to i can arrange them not to get them mixed, the pistons, and other parts seem to be in good shape. The crank has couple of scratches but they don't catch my nail, also i do have 3 more cranks in excellent shape. Little by little they are coming alone. Quote Link to comment Share on other sites More sharing options...
SRDT Posted November 18, 2023 Report Share Posted November 18, 2023 Turbo internals are special unless it's a low pressure XUD9SD, they didn't bother for just a few HP more. Quote Link to comment Share on other sites More sharing options...
Goce Posted November 21, 2023 Author Report Share Posted November 21, 2023 Today i had some time to spare so i got in the big garage to cleaning engine parts. One by one all the parts got cleaned and stored, i only stored the crankshaft i wanted to keep the crankshaft oiled. Then i moved the engine block in to my cleaning tank, first upside down, gave it a quick clean inside and a bit outside. But the outside is very dirty it will get a pressure washing after the machining. After the cleaning the cylinders got honed, my cylinder bore gauge is still in transit so i got me an piston ring and measured the low spot and is not too bad, i'll check when my tool arrives in the meanwhile i'll try to get it resurfaced. My work table is now empty for the next engine block to get disassembled. Quote Link to comment Share on other sites More sharing options...
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