Haynes Peugeot/Talbot Diesel Engine 1982 to 1990 Owners Workshop Manual 1850106967, 9781850106968

Citation preview

Peugeot Talbot Diesel Engine Owners Workshop Manual A

K Legg ting MIMI

Models covered This manual covers the Peugeot/Talbot 1769 cc & 1905 cc (1.7 & 1.9 litre) Diesel engines used in the Peugeot 205 (inc. Van), 305 (inc. Van) & 309 (inc. Turbo Diesel) and in the Talbot Horizon. Does not cover specific application to Peugeot 405 models or 1548 cc Diesel engine used in early 305 models (950-5S2)

aa |=fofe]4

Haynes Publishing Group Sparkford Nr Yeovil Somerset BA22 7JJ England Haynes Publications, Inc 861 Lawrence Drive Newbury Park California 91320 USA

Restoring and Preserving our Motoring Heritage Few people can have had the luck to realise their dreams to quite the same extent and in such a remarkable fashion as John Haynes, Founder and Chairman of the Haynes Publishing Group. Since 1965 his unique approach to workshop manual publishing has proved so successful that millions of Haynes Manuals are now sold every year throughout the world, covering literally thousands of different makes and models of cars, vans and motorcycles.

A continuing passion for cars and motoring led to the founding in 1985 of a Charitable Trust dedicated to the restoration and preservation of our motoring heritage. To inaugurate the new Museum, John Haynes donated virtually his entire private collection of 52 cars. Now with an unrivalled international collection of over 210 veteran, vintage and classic cars and motorcycles, the Haynes Motor Museum in Somerset is well on the way to becoming one of the most interesting Motor Museums in the world. A 70 seat video cinema, a cafe and an extensive motoring bookshop, together with a specially constructed one kilometre motor circuit, make a visit to the Haynes Motor Museum atruly unforgettable experience. Every vehicle in the museum is preserved in as near as possible mint condition and each car is run every six months on the motor circuit.

Acknowledgements Certain illustrations are the copyright of Peugeot Talbot Motor Company Limited and are used with their permission. Duckhams Oils provided lubrication data. Thanks are also due to Sykes-Pickavant who supplied some of the workshop tools, and all the staff at Sparkford who assisted in the production of this Manual.

© Haynes Publishing Group 1990 A book in the Haynes Owners Workshop

Manual

Enjoy the picnic area set amongst the rolling Somerset hills. Peer through the William Morris workshop windows at cars being restored, and browse through the extensive displays of fascinating motoring

memorabilia. From the 1903 Oldsmobile through such classics as an MG Midget to the mighty 'E' Type Jaguar, Lamborghini, Ferrari Berlinetta Boxer, and Graham Hill's Lola Cosworth, there is something for everyone, young and old alike, at this Somerset Museum.

Series

Printed by J. H. Haynes & Co. Ltd, Sparkford, Nr Yeovil, Somerset BA22 7JJ, England All rights reserved. No part of this book may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, recording or by any information storage or retrieval system, without permission in writing from the copyright holder.

ISBN 1 85010 696 7 British Library Cataloguing in Publication Legg, A. K. (Andrew K.) 7942-

Data

Peugeot/Talbot diesel engine owners workshop manual. 1. Cars. Maintenance & repair |. Title 629.28722

ISBN 1-85010-696-7 Whilst every care is taken to ensure that the information in this manual is correct, no liability can be accepted by the authors or publishers for loss, damage or injury caused by any

errors in, or omissions from, the information given.

Haynes Motor Museum Situated mid-way between London and Museum is located just off the A303 at the Haynes Manual) and is open to the round, except Christmas Day and Boxing

Penzance, the Haynes Motor Sparkford, Somerset (home of public 7 days a week all year Day.

Contents Page

Acknowledgements

2

About this manual

2

General dimensions, weights and capacities

6

Introduction to the Peugeot/Talbot diesel engine

7

Buying spare parts

7

General repair procedures

8

Tools and working facilities

9

Conversion factors

11

Safety first!

2

Routine maintenance (a/so see Chapter 8, page

Recommended

163)

13

lubricants and fluids

18

Fault diagnosis

19

Chapter 1 Engine (a/so see Chapter 8, page 163)

22

Chapter 2 Cooling system (a/so see Chapter 8, page

163)

Chapter 3 Fuel and exhaust systems (a/so see Chapter 8, page

78

163)

Chapter 4 Clutch, transmission and driveshafts (also see Chapter 8, page

85 107

163)

114

Chapter 5 Braking system Chapter 6 Steering, wheels and tyres (also see Chapter 8, page

Neen

ee ee

eee ee

Chapter 7 Electrical system (a/so see Chapter 8, page

nn

nN

a

cm

Chapter 8 Supplement: Index

117

163)

eee eee ee

122

163)

ene

Revisions and information on later models a a

163

i

ES 187

Front three-quarter view of Peugeot/Talbot XUD engine. Timing belt cover has been removed

MA Nom

Timing belt Oil filler cap and ventilation hose Injectors Diagnostic socket Temperature sensors

6 i 8

Fast idle thermo unit Thermostat cover Injection pump (Roto-Diese/) io Coolant hose to oil cooler 70 Drivebelt tension adjusting bolt

71 72 73 74 75 716 17

Flywheel Alternator Oil filter Sump Alternator drivebelt Crankshaft pulley Water pump

18 Timing belt intermediate roller 19 Injection pump sprocket 20 Timing belt tensioner 21 Right-hand engine mounting bracket

22 Camshaft sprocket

About

this manual

/ts aim The aim of this manual is to help you get the best value vehicle. It can do so in several ways. It can help you decide must be done (even should you choose to get it done by provide information on routine maintenance and servicing,

from your what work a garage), and give a

logical course of action and diagnosis when random faults occur. However, it is hoped that you will use the manual by tackling the work yourself. On simpler jobs it may even be quicker than booking the car into a garage and going there twice, to leave and collect it. Perhaps most important, a lot of money can be saved by avoiding the costs a garage must charge to cover its labour and overheads. The manual has drawings and descriptions to show the function of _ the various components so that their layout can be understood. Then the tasks are described and photographed in a step-by-step sequence so that even a novice can do the work. Unlike most Haynes manuals, which cover a particular vehicle in different trim levels and engine sizes, this book covers one engine and its associated equipment as fitted to a range of vehicles. Items which are common to Diesel and petrol models — eg bodywork, transmission and running gear — are not covered in this book.

/ts arrangement The manual is divided into eight Chapters, each covering a logical sub-division of the vehicle. The Chapters are each divided into Sections, numbered with single figures, eg 5; and the Sections into paragraphs (or sub-sections), with decimal numbers following on from the Section they are in, eg 5.1, 5.2, 5.3 etc.

It is freely illustrated, especially in those parts where there is a detailed sequence of operations to be carried out. There are two forms

of illustration: figures and photographs. The figures are numbered in sequence with decimal numbers, according to their position in the Chapter — eg Fig. 6.4 is the fourth drawing/illustration in Chapter 6. Photographs carry the same number (either individually or in related groups) as the Section or sub-section to which they relate. There is an alphabetical index at the back of the manual as well as a contents list at the front. Each Chapter is also preceded by its own individual contents list. References to the ‘left’ or ‘right’ of the vehicle are in the sense of a person in the driver's seat facing forwards, but note that, in Chapter 1, references to the ‘front’ of the engine are in respect of the timing belt end with the engine removed from the vehicle.

Unless otherwise stated, nuts and bolts are removed anti-clockwise, and tightened by turning clockwise.

by turning

Vehicle manufacturers continually make changes to specifications and recommendations, and these, when notified, are incorporated into our manuals at the earliest opportunity. Whilst every care is taken to ensure that the information in this manual is correct, no liability can be accepted by the authors or publishers for loss, damage or injury caused by any errors in, or omissions from, the information given.

Project vehicles The vehicles used in the preparation of this manual, and appearing in many of the photographic sequences, were a Peugeot 205 GRD and a Talbot Horizon LD. The vehicle used in the preparation of the Supplement (Chapter 8) was a Peugeot 309 GRD Turbo.

General dimensions, weights and capacities Dimensions Overall length: PAOSe enact erece Rana tep eros concect alae con: one: ORDEAL EEBEE Seca canecross erea ouO MSaeee BO Dacca cates eee ee io oe GREE eR. Ps BOO as Picea dt dodccuel ane eee thet: Es eee a ce MOE, oteee cee FIORIZOM essac cara enenna te meme toeeeeaae cecaareetee reece tenettee csmtnt cece sapaeeaechetes Overall width: 205 except (GRD Bates eee nee eeeE MetomntneeesRenee ZOSIG RD x,oisn5 ate Rete ere oe a ots eee ren pe eeeiaee BODire sds aus ceca ieee ree acetate sox tac teerterte ns sanaee S, Ngvesaen x sss pear ease ee SO rea: ce, Meme eee a te a at ans Heine Ata eas Pus cote eee FLONIZOM: oesseats cetente teestcmeenarteet arse Mee aunt asrattacaseet sree oushct ceri himeen act Overall height: ZOOS Except Vai: Is bt elzlzle| l=els >| ellals

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Fig. 7.14 Wiring socket locations on fuse/relay board — Peugeot 205

Fig. 7.15 Wiring socket locations on fuse/relay board — Peugeot 309

The socket code corresponds to the connector suffix in Figs. 7.11 and 7.12

The socket code corresponds to the connector code suffix WIA, LAS

Chapter 8 Supplement: Revisions and information on later models Contents b action Reet atesee enccegh teat catbrnasgaeeeatasess

1 2 3

crete cece cteasgasceanvactscnscosectectesarenestscuserurrsa

4

BEDEROCUUICERO Neerste eae oases sacs Specifications Routine maintenance

Turbocharger - examination and renovation Fuel injection pump dust shield (CAV/Roto-Diesel) Fuel injection pump (turbocharged models) — description Fuel injection pump (turbocharged models) - removal and

Maintenance intervals (1989 on)

SVG INN eee creo cccae aces eect

Timing belt cover, tensioner and associated component modifications — all models from 1988 Oil level and temperature sensors — general

refitting Fuel injection pump (later Lucas CAV/Roto-diesel) — checking and adjusting the static timing Clutch and transmission ............cccssesssssessssecscescscsseessssenscscossesenessesssenseeses

h

Clutch release mechanism (with BE3 gearbox) - description BE3 gearbox - description

Cylinder head (KUD7T) - removal and refitting

8

mn ceccse-ccrtcccseccerccceecsscsectssosccoeats ccsursnccseavervarrastagsnevsccenersece Electrical SySte Wiring diagrams - later models

Cylinder head gasket identification - all models Cylinder head bolt identification — all models Valve springs — later models Oil pump (later models) — removal and refitting

Engine right-hand mounting rubber (all models) — removal and refitting Crankshaft and associated components - later XUD7 on Peugeot 205 Engine (KUD7T) - dismantling for overhaul Engine (XUD7T) - initial start-up after overhaul

COONIMG SY SCCM o.ose.ceccecncesccescsczesccoevcoessasccsosoarsnzsseeerseerseensssensevossasceneesezso¥stsss

1.

This Supplement contains information which is additional to, or a revision of, material in the preceding Chapters. Most of it relates to the XUD7T engine fitted to the Peugeot 309 GRDT, and associated equip-

5

ment, but some items apply to all models.

6

The Sections in the Supplement follow the same order as the Chapters to which they relate. The Specifications are all grouped together for convenience, but they too follow Chapter order.

General description - 309 GRD Turbo: Temperature-sensitive switches and senders (all models) —

sealing Fuel and exhaust SYSteMG..............ccscssssssesseseseseseeeseenensensstssseseserenseneses

Introduction

Air cleaner element (309 GRD Turbo) - removal and refitting Fuel filter (later models) - description

Turbocharger - description Turbocharger - precautions

Turbocharger - removal and refitting

It is recommended that before any particular operation is undertaken, reference be made to the appropriate Section(s) of the Supplement. In this way any changes to procedures or components can be noted before referring to the main Chapters.

a 2

Specifications

These Specifications are supplementary to, or revisions of, those at the beginning of the preceding Chapters

Engine - all models General Additional designations: 1.7 (Normally aspirated) ........cecsecsecseesssnesneeneeneensssnesnsssecsscsneensentenneeneeseesscsessess 1.7 (turbocharged) .........ssssecreseereee cc eee neatsara visbccnveapiscadse aeceieEs A Ge

XUD7/A9A XUD7T (also known as XUD7TE, A8A and A8B)

XUDSA/D9A

Valves Stem diameter: Exhaust Valve guide bore (fitted)......-csssssssssssssnussesssssessecnssnsesseesssunsessesennnsressssssssssssesnngnaess Valve head diameter:

Inlet, UP to OCtObEr 1986 .....s.sscccsssssessneesssnseenssssesensnssessnnerennnnasccesssscesssnessen

Inlet, October 1986 on Exhaust, all MOCEIS......cccsecsssssecsessscsessessecscessennecsesseesssssssneenecsesssenennennegascassoeses

8.005 mm (0.3154 in) 7.985 mm (0.315 in) 8.020 mm (0.316 in) 36.0 mm (1.42 in) 38.5 mm (1.52 in) 33.0 mm (1.30 in)

164 se Nee

hw

Chapter 8 i

Supplement: Revisions and information on later models Cae a

Seat angle: Inletttinitol@ctobend| ISG sessemeceseertetecetsre stsrrecestesctertcarsncceerczenesesenes Inlet October WSSE Otiiccrsccccsscescestecstss-sececiserseseesreestereecteesseersy azecserorarsavescsare ExhatistralilitmoGeSmeets csscccescascctesecccceacc erates stecemecccverceterccrecsrestes ateers

Torque wrench setting Engine right-hand mounting rubber to DOAY .........eeessesesesestesesesseessssesenesssees

120% 90° 90°

Nm 40

Ibf ft 30

Engine - XUD7T General Compression ratio Cubic capacity............ Maximum torque....... IVa XIU IND OWOCMiscccecacncsceneecs cascctessteacsc Senctcsteadactedeeces cecaosasaatesenssavetsne=cevseetcesoesseeete Maximum speed: NO [OGG cin ssccectisdscececnccese saree veece- eae eae see Paespecan te TaeaPtsate opto eme sive ode eae FUELMMO AGE esas scsevetyeesos casescubsrcesehscMavecan dnest eee aes ance coeSee ae eae gC

saben

22.0:1

1769 cc (107.9 cu in) 157 Nm (116 Ibf ft) @ 2100 rpm 57.5 kW @ 4300 rpm (77 bhp) 4900 rpm 4300 rpm

Pistons GUdGeON"plindianneteterres csccsecerertsctecttteccece tessecerteccnceeretererreeserteettetccrernees

28.0 mm (1.1032 in)

Crankshaft Thrustwasher thickness: S Ca CEC teccrncersecreseetscsererrctres eeretree rereeTeTeRCROUERET TTTCETRC Teter ran tees ONVSRSIZO mrss ees ce rccte te eae em eee ae ECD rc eee

1.855 mm (0.073 in) 1.955, 2.005 and 2.055 mm (0.077, 0.079 and 0.081 in)

Valves Valve timing (zero clearance, lift of 0.8 mm/0.032 in):

WUE tOOSN artaterceters cesses astavecccsctre creators csceceatoaanscoucuevsssarcs srstesveccoeacaneet tectuaresees Inlet closes............ Exhaust opens Exhaust closes

So 76° 89° 46°

SO 30’ 30’ 30’

SHADIC. ABDC BBDC ATDC

Cooling system - all models except Turbo, April 1987 on General Temperature warning switch operating teMPerature .......ccesesesseceseceeseeeens Electric cooling fan cut-in temperature: ISHS PECd MAS Re et OE SL 2 ee 2nd speed Electric cooling fan cut-out temperature: GSUES DG CC ccecesrece eae sees ceecu caeece stateaseey ruseaceassveceuscivescasctswtessdeaotece teopeescteseetae tncee ZINA'SPS ORs cee eee ct a reece ate as sc eres ce Reaction

110°C (230°F) 932 (19925) S72C(2Z0725) 88°C (190°F) 92°C (1982F)

Cooling system - 309 GRD Turbo General Capacity

7.8 litres (13.7 pints)

Thermostat opening temperature ...

S92CKI922R)

Electric cooling fan cut-in temperature: WSBESCC Cletes evereneeeseste ester see ese ere S Re eT Ter ene DINGS DC CG eeeees scecatecevsnc cress cvscesoasecsabeotuccscvas tenscvesteaseacdsarvestestesecws eer eee eee

S712© (2072) 101°C (214°F)

Fuel and exhaust systems - 309 GRD Turbo General EUS ltAMKI CAPACITY vn scree crests sccecseerecrs antec

eieeteeucree Corea eraeamere eae

meee

55 litres (12 gallons) approx

Turbocharger Wa Greer seedsatcck cs gustecartcsas Roctacaatensasvecacetcareeeces otha uesarin eeseee eeseter ee

KKK K14 0.85 bar (12.3 Ibf/in?)

Injection pump WlAKG iissessctssressaccevessarseazess Type number

Lucas CAV/Roto-Diesel

R8443B620A

Fuel injectors OPENING! PLESSUMS Bee ices cosceevectcscsantencovssoccsvscsdersuscssses MteEstheedommes eats ee

130 + 5 bar (1885 + 73 Ibf/in?)

Torque wrench setting

Nm 45 20

TUDO MMOUM*IMG DOl(Sterrcse

coc -scsece-xes-cesesss scseucecnes ss cneeecteeettee ee merece eee

TUTHOLOllifeea: anenetumrMDlDESmeceiectcevecsnecteecsesceceestearereeeeee eevee eee

Ibfft 33 15

ee

165

Under-bonnet view of a Peugeot 309 GRD Turbo

1 2 3. 4

§

Brake fluid reservoir Boost pressure hose Air intake trunking Crankcase ventilation oil trap Vacuum pump

6 7 8 9 10

Fue/ filter Expansion tank filler cap Preheater plug relay Battery Air cleaner inlet hose

11 Power steering fluid reservoir 12 Radiator cap 13 Air cleaner 14. Thermostat housing 15 Dipstick/oil filler cap

16 17 18 19 20

Oj filter Fuel injection pump Fuel injectors Throttle cable Headlight beam adjusters

166 ee

Chapter8 ee

Supplement: Revisions and information on later models SS Se

eee

Clutch - 309 GRD Turbo

General ETiGULON DlALEIG AIGLG lpecrecrcecscthereeesecersctacettar-toreserscvensemnes czrerrescenscitreseerseesretas

215 mm (8.5 in)

Manual transmission type BE3 General Superseding BE1 progressively from 1989 model year

Application Code:

BE3/4 BE3/5 2.0 litres (3.5 pints)

Steering, wheels and tyres Front wheel alignment 205, 1988 model year on:

5.0 + 1 mm (0.20 + 0.04 in) toe-in

0° 40’ + 30’ ora Seem 82935 Or

Steering axle inclination 309, 1990 model year on (except Turbo):

3.7 + 1mm (0.15 + 0.04 in) toe-out

Steeningiaxle imeli mathe mcs seserecntaeteee-t< Sete cadeesessns:..seisomecentetrmeerseress 309 GRD Turbo:

O0Sia= 30K 0940" 2530) So 202230" 3.25 + 1 mm (0.13 + 0.04 in) toe-out

=O aasOu OA 0ie2=3 0" 9° 45’

Wheels and tyres - 309 GRD Turbo Wheel size: 5.5J14FH 4-24 5.5J14CH 4-24 175/65 R 14H

Alloy Tyre size Tyre pressure

3

2.0 bar (29 Ibf/in?) front and rear

Oil level and temperature sensors - general

Routine maintenance

5

An oil level sensor is not fitted to all models. When it is fitted, it is

located on the rear face of the engine, at the flywheel end — see Chapter

Maintenance intervals (1989 on) 1

1, photo 22.18B.

From 1989 model year, maintenance intervals are extended from

5000 miles (7500 km nominal) to 6000 miles (10 000 km nominal) and multiples thereof. The time interval (six months, one year etc) to

unchanged.

6 An oil temperature sensor is fitted to some models from 1985. When fitted, it is next to the oil pressure sensor, itself located just above the oil filter.

2 The maintenance interval for the 309 GRD Turbo remains at 5000 miles/7500 km.

4

Engine

General 1 Few changes have been made to the XUD significant development has been the introduction engine (XUD7T). The design of the turbo engine normally aspirated version, but components such pistons and connecting rods are uprated.

engine. The most of a turbocharged is the same as the as the crankshaft,

Timing belt cover, tensioner and associated component modifications — all models from 1988 2 Thetiming belt cover fixings were modified slightly at the beginning of 1988 model year. The hairpin securing clip is no longer fitted, and the number of fixing studs is increased from one to two. 3 Atthe same time modifications were made to the tensioner roller, the injection pump sprocket and (on Bosch pumps only) the injection pump front bearing.

4

Old and new pattern tensioner rollers are fully interchangeable. The

other components are not interchangeable.

4.7 Disconnecting the inlet manifold-to-injection pump hose

Chapter 8

Supplement: Revisions and information on later models

167

Later assembly

Earlier assembly

Fig 8.1 Earlier and later pattern timing belt covers (Sec 4) 2

11. The XUD7T engine cylinder head gasket is identified by two notches on the gasket centre line (’E’ in Fig. 1.8, Chapter 1). Thickness identification is still by the number of notches in the corner of the gasket, as described in Chapter 1, Section 9.

Cylinder head bolt identification — all models Early type cylinder head bolts (up to 1986), which are not subject to 12 the angle-tightening procedure, have a plain shank. Bolts fitted from 1987, which are subject to angle-tightening, have 13. coarse spiral grooving on the upper shank. Photo 26.39A in Chapter 1 shows this clearly.

During 1989 the hexagon head bolts were replaced by Torx head 14 bolts. The angle-tightening procedure is unchanged and the bolts are interchangeable, either singly or in sets (photo). 15.

dae i

4.14 Angle-tightening a Torx head cylinder head bolt

Bolts fitted to turbo engines (KUD7T) are a different length; they

are identified by a dot marking on the bolt head.

Valve springs - later models 16

From 1989 model year, single valve springs are fitted instead of the

double ones used previously.

Cylinder head (XUD 7T) — removal and refitting

7 Proceed as in Chapter 1, Section 9, but when removing the cylinder -head disconnect the following additional items: (a) (b) (c)

8

Turbo oil feed and return pipes (see Section 6) Inlet manifold-to-injection pump hose (photo) Fuel preheater (when fitted)

The turbocharger itself may be removed with the manifolds.

9 After refitting and before initial start-up, prime the turbo lubrication circuit by disconnecting the stop solenoid lead at the fuel pump and cranking the engine on the starter for three ten-second bursts.

Cylinder head gasket identification — all models

In addition to the three thicknesses of gasket listed in Chapter 1, 10 may Section 9, a fourth thickness, identified with four notches or holes, a having engines ioned recondit to fitted is be encountered. This gasket in). (0.033 mm 0.84 of excess in on piston protrusi

If the old double springs are to be renewed, the new single springs 17. may be fitted.

Oil pump (later models) - removal and refitting

From April 1987, the oil pump spacer and location dowel are no 18 longer fitted. The height of the pump is increased to compensate.

Anew pump may be fitted in place of an old one provided that the 19 spacer and dowel is discarded. Thicker washers (part No 6962.28) must be fitted under the heads of the oil pump bolts.

On XUD7T engines, a thin spacer is still fitted between the oil 20 pump and the block.

Engine right-hand mounting rubber (all models) removal and refitting

Gain access to the mounting rubber as described in Chapter 1, 21 Section 17.

Chapter 8

168

Supplement: Revisions and information on later models

4.22A Home-made tool for removing the engine mounting rubber

4.22B Engine mounting rubber in position, showing slots

4.23A Using the tool to unscrew the rubber

4.23B Removing the engine mounting rubber

22

Crankshaft and associate components — later XUD7 on Peugeot 205

Makeup atool similar to that shown to engage with the slots in the

rim of the rubber (photos). Assuming that the rubber is being renewed,

the new component can be used as a guide when making the tool.

25 From June 1988, the XUD7 engine fitted to the Peugeot 205 has the same crankshaft as that fitted to the XUD7T engine. This later crankshaft is steel (the old one was cast iron) and is readily identified by

23

Unscrew the old rubber from the body using the tool (photos).

24 Refit by reversing the removal operations, tightening the rubber firmly to the body using the tool. (The tightening torque is given in the Specifications as a guide, though a torque wrench cannot be used with the home-made tool shown.)

having only four balance weights as opposed to eight. 26 The main and big-end bearing shells, thrustwashers and connecting rods are all specific to the crankshaft. A cast iron crankshaft, with the appropriate shells and thrustwashers, may be fitted in place of a steel one without changing the connecting rods. A steel crankshaft must not

Fig 8.2 Cast iron crankshaft (left) and steel crankshaft (right) (Sec 4)

Chapter8

Supplement: Revisions and information on later models

169

Fig 8.3 Piston cooling oil jets in crankcase - XUD7T engine (Sec 4) be fitted in place of a cast iron one unless the connecting rods are renewed too.

Engine (XUD7T) - dismantling for overhaul 27 The procedure is as described in Chapter 1, Section 22, with the addition that the turbocharger must be removed at the same time as the manifolds. 28 If complete dismantling is being undertaken, remove the piston cooling oil jets from the crankcase and clean up or renew them (Fig. 8.3). 29

Note that any other components are specific to the turbocharged

engine and are not interchangeable with those from normally-aspirated engines, even though they may appear to be the same.

Engine (XUD7T) - initial start-up after overhaul Prime the turbo lubrication circuit before start-up by disconnecting 30 solenoid lead at the fuel pump and cranking the engine on the stop the starter for three ten-second bursts.

5

Cooling system

General description - 309 GRD Turbo 1 The cooling system on Turbo models is the same as that described in Chapter 2, but additionally a coolant-fed oil cooler, similar to that used on XUD9 engines, is fitted. The thermostat housing is modified in

consequence.

Temperature-sensitive switches and senders (all models)

- sealing

2 According to model and equipment, various temperature-sensitive switches and senders are fitted in the thermostat housing. 3.

When fitting a new switch or sender, it is important to coat its

Fig 8.5 Fuel preheater (1) and other components on the rear of the XUD7T engine (Sec 6)

threads with a suitable sealant (Loctite Formseal or equivalent) to avoid

subsequent coolant leaks.

Ln

6

Fuel and exhaust systems SS ee ee a

Air cleaner element (309 GRD Turbo) - removal and refitting 1

Proceed as in Chapter 3, Section 3, but note that the air cleaner

cover is secured with spring clips instead of with a screw.

Fuel filter (later models) - description

2 Commencing in 1990 model year, the fuel preheating function of the filter now takes place in a housing on the cylinder block. Coolant is therefore no longer piped to the filter base.

4

Turbocharger

5

Inlet manifold

6

Exhaust outlet flange

Turbocharger - description

3. A turbocharger is fitted to. the XUD7T engine. It increases engine efficiency by raising the pressure in the inlet manifold above at-

mospheric pressure. Instead of the air simply being sucked into the cylinders it is forced in.

4 Energy for the operation of the turbocharger comes from the exhaust gas. The gas flows through a specially-shaped housing (the turbine housing) and in so doing spins the turbine wheel. The turbine wheel is attached to a shaft, at the end of which is another vaned wheel known as the compressor wheel. The compressor wheel spins in its own housing and compresses the inducted air on the way to the inlet

manifold.

170

Chapter 8

Supplement: Revisions and information on later models 5 Boost pressure (the pressure in the inlet manifold) is limited by a wastegate, which diverts the exhaust gas away from the turbine wheel in response to a pressure-sensitive actuator (photo).

6 The turbo shaft is pressure-lubricated by a feed pipe from the main oil gallery. The shaft ‘floats’ ona cushion of oil. A drain pipe returns the oil to the sump.

Turbocharger — precautions 7 The operates at extremely high speeds and temperatures. Certain precautions must be observed to avoid premature failure of the turbo or injury to the operator. 8 Do not operate the turbo with any parts exposed. Foreign objects falling onto the rotating vanes could cause extensive damage and (if ejected) personal injury. 9 Donot race the engine immediately after start-up, especially if it is cold. Give the oil a few seconds to circulate.

6.5 View of compressor end of turbocharger, showing wastegate

10 Always allow the engine to return to idle speed before switching it off - do not blip the throttle and switch off, as this will leave the turbo spinning without lubrication.

actuator control pipe (arrowed)

= ae

6.16C Oil feed pipe bracket

6.16D Oil return hose connection to turbo pipe (arrowed)

Chapter8

Supplement: Revisions and information on later models

171 2S

11. Allow the engine to idle for several minutes before switching off after a high-speed run. 12 Observe the recommended intervals for oil and filter changing, and use areputable oil of the specified quality. Neglect of oil changing, or use of inferior oil, can cause carbon formation on the turbo shaft and subsequent failure.

Turbocharger — removal and refitting

18 Lower the vehicle. Remove the vacuum hoses (Chapter 5, Section 3).

19

Remove

—L—K—K

pump, its drivebelt and

the trunking which joins the air cleaner to the inlet

manifold, and the associated crankcase ventilation hoses (photo).

20 Remove the small hose which joins the inlet manifold to the injection pump.

13

Disconnect the battery earth lead.

21.

14

Raise and support the vehicle. Remove the engine undertray.

Remove the seven bolts which secure the inlet manifold, using a 22 6 mm Allen key. The bolts are very tight, and access is not good. The middle bolt hole is slotted, so if wished the middle bolt can just be slackened.

15 Remove the exhaust system. Recover the two dowels locate the exhaust downpipe on the turbo outlet flange.

which

Slacken the hose clips on the turbo-to-inlet manifold hoses.

16 Prepare for some oil spillage. Disconnect the turbo oil feed pipe and return hose from the block. Also unbolt the bracket which secures the feed pipe. Disconnect the return hose from the pipe on the turbo and remove it (photos).

Remove the inlet manifold. The gasket is shared with the exhaust 23 manifold, so it will stay in place (photo).

17. Unbolt and remove the engine bottom mounting-to-crossmember link (photo) The engine will move forwards slightly when this is done.

Disconnect the oil feed pipe from the top of the turbo. Remove the 25 pipe. Note the strainer in the pipe (photos).

6.23 Removing the inlet manifold

24

Remove the short hose from the turbo outlet (photo).

6.24 Turbo outlet hose

Chapter 8

172

Supplement: Revisions and information on later models

6.27 Turbo bottom mounting bolts (arrowed)

6.26 Turbo top mounting bolt 26 Remove the turbo-to-manifold above (photo).

27

bolt which

is accessible

from

Raise the vehicle again. Remove the two other turbo-to-manifold

bolts (photo). Lower the vehicle. 28

Unbolt and remove the heat shield from the bulkhead (photo).

29 Manipulate the turbocharger and lift it out from above, exhaust end first (photo). It is a tight fit, but it can be done. It may help to have an assistant pull the engine forwards slightly. 30 If it is wished to renew the manifold gasket, the exhaust manifold must now be removed. 31 Refit by reversing the removal operations, noting the following points:

(a) (b) (c)

If anew turbocharger is being fitted, change the engine oil and filter. Also renew the strainer in the oil feed pipe. Donot fully tighten the oil feed pipe unions until both ends of the pipe are in place. Before starting the engine, prime the turbo lubrication circuit by disconnecting the stop solenoid lead at the fuel pump and cranking the engine on the starter for three ten-second bursts (photo)

32 After initial start-up, do not race the engine. Inspect the turbo and its lubrication pipes for oil leaks. Stop the engine and check the oil level. 33

Anew turbo should be run-in like any other major mechanical unit.

Turbocharger — examination and renovation 34 With the turbocharger removed, inspect the housings for cracks or other visible damage. 35 Spin the turbine or the compressor wheel to verify that the shaft is intact and to feel for excessive shake or roughness. Some play is normal since in use the shaft is ‘floating’ on a film of oil. Check that the wheel vanes are undamaged.

36 On the KKK turbo the wastegate and actuator are integral and cannot be checked or renewed separately. — 37 If the exhaust or induction passages are oil-contaminated, the turbo shaft oil seals have probably failed. 38 No DIY repair of the turbo is possible. A new unit may be available on an exchange basis.

Fuel injection pump dust shield (CAV/Roto-Diese/) 39 From April 1988, the CAV/Roto-Diesel pump is fitted with a dust shield to protect the front bearing seals.

Chapter8

Supplement: Revisions and information on later models

Mee vice o

pea

6.43A Electromagnetic timing device (arrowed) on Turbo fuel pump

6.43B Electromagnetic timing contact on the fast idle control lever

173

Chapter 8

174

Supplement: Revisions and information on later models

as, 6.47 The white plastic disc fitted to later injection pumps

6.48 Home-made TDC setting tool

40 I|f anearlier type pump is removed for any reason, the opportunity should be taken to obtain and fit a dust shield kit.

Fuel injection pump (turbocharged models) — removal and refitting

Fuel injection pump (turbocharged models) - description

45 Proceed as in Chapter 3, Section 4, but additionally disconnect the boost pressure hose from the overfuelling device.

41 Theinjection pump fitted to turbocharged models is similar to that fitted to normally aspirated models, but incorporates the following

additional features. 42

An overfuelling device varies the quantity of fuel injected in

response to turbo boost pressure. Pressure is sensed via a hose connected to the inlet manifold (photo).

46 Refit by reversing the removal operations. Check the pump timing if necessary as described in this Section.

Fuel injection pump (later Lucas CA V/Roto-Diesel) checking and adjusting the static timing 47 From 1987 a modified pump was fitted to some engines. The pump can be recognised by the presence of a white plastic disc on its

43 An electromagnetic timing system advances injection timing when the engine is cold. The system is switched off by a contact

front face. A timing value is engraved on the disc (photo). (If the disc is

activated by movement of the fast idle control lever (photos).

blue, this denotes a factory reconditioned pump.)

44 _ These additional devices cannot be adjusted or checked by the home mechanic.

48

The pump timing is now carried out at TDC. Only one dial test

indicator is needed, but it will be necessary to make up a bent rod or

Fig 8.6 Dust shield kit for Lucas CAV/Roto-Diesel pump (Sec 6) 1

Plastic cup

2

Rubber seal

Chapter8

Supplement: Revisions and information on later modeis

175

SSS

RX fT SSS SSS

SSS

Dy

6.51 TDC setting tool (arrowed) inserted into the hole on the block

similar tool to enter the TDC setting hole. The tool made up in the workshop consisted of an M8 bolt with the threads filed away, attached to a piece of welding rod (photo). Alternatively the starter motor can be removed and a twist drill or straight rod can be used — see Chapter 1, photo 22.26. Prepare the engine as described in Chapter 3, Section 5, para49 graphs 1 to3.

50

Turn the engine to bring No 4 cylinder (timing belt end) to TDC on

compression. To establish which cylinder is on compression, either remove No 4 cylinder heater plug and feel for pressure, or remove the valve cover and observe when No 1 cylinder valves are ‘rocking’ (inlet

open and exhaust closing).

Insert the TDC setting tool into the hole and turn the engine back 51 and forth slightly until the tool enters the hole in the flywheel. Leave the tool in position (photo). Remove the inspection plug from the top of the pump. Position a 52 dial test indicator so that it can read the movement of a probe inserted into the hole. If a magnetic stand is to be used, the absence of ferrous metal in the vicinity poses a problem; a piece of steel plate can be bolted to the engine mounting or valve corner to carry the stand (photo).

Fig 8.7 Timing probe details — later Lucas CAV/Roto-Diesel pump (Sec 6) a_ x

Timing piece Timing value (engraved on disc)

y

95.5+0.01 mm

(3.7600 + 0.0004 in)

Insert a probe into the inspection hole so that the tip of the probe 53 rests on the rotor timing piece (Fig. 8.7). Position the dial test indicator to read the movement of the probe.

Remove the TDC setting tool. Turn the engine approximately a 54 quarter turn backwards. Zero the dial test indicator.

Turn the engine forwards slowly until the TDC setting tool can be 55 re-inserted. Read the dial test indicator: the reading should correspond

to the value engraved on the pump disc (+ 0.04 mm).

56

‘If the reading is not as specified, proceed as follows.

Disconnect the injector pipes from the pump. Slacken the pump 57 mounting nuts and bolts and swing the pump away from the engine. Zero the dial test indicator.

JS

6.52A Removing the inspection plug from the top of the pump

6.52B Dial test indicator positioned over the inspection hole

176

Chapter8

Supplement: Revisions and information on later models

LSTs

7.5B Topping-up the oil in the BE3 gearbox 7

Clutch and transmission

Clutch release mechanism (with BE3 gearboxes) description 1. Instead of the clutch release fork pivoting on a ball stud as in the BE1 gearbox, in the BE3 gearbox a pivot shaft is used. (Fig. 8.8).

2 Clutch adjustment procedure is unchanged. Overhaul procedures will be found in the relevant manual for petrol-engined models.

BE3 gearbox - description 3 The BE3/4 and BE3/5 gearboxes progressively replaced the BE1/4 and BE1/5 gearboxes, from the beginning of 1989. The main difference

is in the gearshift components. The driver will notice that reverse gear is now in the same plane as 2nd and 4th — opposite 5th, when applicable — and that the lifting collar below the gear knob is now obsolete for reverse selection.

Fig 8.8 Clutch release pivot shaft - BE3 gearbox (Sec 7) a_

Bearings

4 Overhaul procedures will be found in the relevant manual for petrolengined models.

5

The oil filler/level plug for the BE5 gearbox is in the end cover; it is

accessible through the left-hand wheel arch (photos).

58 With the engine still at TDC, slowly swing the pump back towards the engine until the dial test indicator displays the value engraved on the pump disc. In this position tighten the pump mountings, then remove the TDC setting tool and recheck the timing as just described.

8

59 When the timing is correct, reconnect the injector pipes, remove the dial test indicator and TDC setting tool and refit the inspection plug.

Wiring diagrams — later models

60 Refit any other disturbed components, remove the plastic bag from the alternator and lower the vehicle to the ground.

1 Wiring diagrams for later models are provided in this Section. For the key, and for guidance in use of the diagrams, refer to the key for Figs. 7.4 to 7.9 in Chapter 7.

Electrical system

177 i

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ORT

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lit)

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