Fixing, rebuilding 4 cylinder diesel engines XUD9TE

[GoceKU]

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.

 

[GoceKU]

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.

 

[GoceKU]

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.

 

[GoceKU]

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.

 

[GoceKU]

Today after work i took apart one of the engines i'm fixing, i did leave the crank, rods and pistons in, and plan to wash it out well after. I did take off the oil pan, oil pump and few other accessories to make it fit. I took it to a friend's machinist shop, he has a good size mill and we resurfaced it, it did clean up at 0,040mm but we took one more cut to get better surfice finish. Total that we took off 0,080mm and now is perfect ready for a new head gasket. Lifting it, carrying it in the little niva is hard work. I did use my engine crane to take it out of the boot.

 

[GoceKU]

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.

 

[mattthemuppet2]

that's clever!

 

[GoceKU]

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.

 

[GoceKU]

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.

 

[GoceKU]

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.