2B 1 2 3 4 5cx.podolsk.ru/bx/docum/haynes/engine171_159.pdf · 2B Chapter 2 Part B: 171 and 159...

2B

Chapter 2 Part B:171 and 159 enginesIncluding engine variants B1A/A, B2C, BDY, D2A, D2E, D2F, D6A, D6D and DKZ. For model applications refer to Specifications

Model applicationBX 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171 B or C (XU5S)BX 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159 A (XU9S)BX 16 RE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1A/ABX 16 (except TXi model - from September 1988) . . . . . . . . . . . . . . . B2C (XU52C)BX 16 - fuel-injected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BDY (XU5M 3Z)BX 19 TRS (from July 1986) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2A (XU92C)BX 19 TRS/TZS (for 1990) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2E (XU92C+)BX 19 TZS (from 1991) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2F (XU92C+)BX 19 GTi (up to 1991) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D6A (XU9J2)BX 19 GTi (from 1991) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D6D (XU9J2)BX 19 TZi with catalytic converter . . . . . . . . . . . . . . . . . . . . . . . . . . . DKZ (XU9JAZ)

171 engineGeneralType . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Four-cylinder, in-line, OHC, liquid cooled, transverse mountingBore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83.0 mmStroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73.0 mmCapacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1580 ccCompression ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5:1Firing order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 3 - 4 - 2Location of No 1 cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . At clutch end of blockDirection of crankshaft rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clockwise viewed from pulley endMaximum power DIN (BHP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 (94*) at 6000 rpmMaximum torque DIN (lbf ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96.9 at 3500 rpm*171 C engine from October 1984

Camshaft - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Camshaft drivebelt - removal and refitting . . . . . . . . . . . . . . . . . . . . 6Cylinder head - dismantling, decarbonising, inspection and

reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Cylinder head - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . 8Cylinder liners - checking protrusion . . . . . . . . . . . . . . . . . . . . . . . . . 18Engine - complete dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Engine - complete reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Engine dismantling - ancillary items . . . . . . . . . . . . . . . . . . . . . . . . . 11Engine dismantling - general information . . . . . . . . . . . . . . . . . . . . . 10Engine - examination and renovation . . . . . . . . . . . . . . . . . . . . . . . . 14Engine - initial start-up after overhaul . . . . . . . . . . . . . . . . . . . . . . . . 22

Engine - preparation for reassembly . . . . . . . . . . . . . . . . . . . . . . . . . 17Engine reassembly - general information . . . . . . . . . . . . . . . . . . . . . 16Engine - reconnection to transmission . . . . . . . . . . . . . . . . . . . . . . . 20Engine - separation from transmission . . . . . . . . . . . . . . . . . . . . . . . 12Engine/transmission - refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21Engine/transmission - removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9General information and precautions . . . . . . . . . . . . . . . . . . . . . . . . 1Major operations possible with engine in vehicle . . . . . . . . . . . . . . . 3Major operations requiring engine removal . . . . . . . . . . . . . . . . . . . . 4Oil filter - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Valve clearances - checking and adjustment . . . . . . . . . . . . . . . . . . 5

2B•1

Specifications

Contents

Easy, suitable fornovice with littleexperience

Fairly easy, suitablefor beginner withsome experience

Fairly difficult,suitable for competentDIY mechanic

Difficult, suitable forexperienced DIYmechanic

Very difficult,suitable for expert DIYor professional

Degrees of difficulty

54321

Cylinder headType . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Aluminium alloy, in-line valves and five bearing camshaftMaximum allowable distortion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 mmValve seat angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90ºValve guide bore diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.0 to 8.022 mm

ValvesStem diameter:

Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.98 to 7.83 mmExhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.96 to 7.81 mm

Head diameter:Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40.0 mmExhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32.0 mm

Length:Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107.49 ± 0.1mmExhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106.92 ± 0.1mm

Springs:Wire diameter: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4 mmLength under load:

Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40.5/41 mm/kgExhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30.0/80 mm/kg

Valve clearance (cold):Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 to 0.25 mmExhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.35 to 0.45 mm

Adjustment shim thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.225 mm to 3.025 mm (in steps of 0.025 mm) 3.100 mm to 3.550 mm(in steps of 0.075 mm)

Valve timingValve lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4 mm or 9.7 mm (from December 1983)Inlet opens* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0º 48’ BTDCInlet closes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37º ABDCExhaust opens* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35º 36’ BBDCExhaust closes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2º 12’ ATDC*With valve clearance of 1.0 mm

CamshaftEndfloat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.07 to 0.16 mm

Crankshaft and main bearingsNumber of bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FiveCrankshaft endfloat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.07 to 0.27 mmThrustwasher thicknesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30, 2.35, 2.40, 2.45, 2.50 mmMaximum allowable ovality of crankpins and journals . . . . . . . . . . . . . . 0.007 mmCrank journal dimensions:

Standard diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60.0 to 59.981 mmRegrind diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59.7 to 59.681 mm

Standard main bearing thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.842 mmReplacement main bearing thickness after regrind . . . . . . . . . . . . . . . . 1.992 mmCrankpin dimensions:

Standard diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.0 mmRegrind diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.7 mmStandard bearing thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.817 mmReplacement bearing thickness after regrind . . . . . . . . . . . . . . . . . . . 1.967 mm

Connecting rodsSmall-end bore diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.0 mmSmall-end to gudgeon pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.020 to 0.041 mmBig-end bore diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48.655 mm

Cylinder linersType . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cast iron, wet typeLiner base seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O-ringLiner protrusion - clamped or without seal . . . . . . . . . . . . . . . . . . . . . . . 0.08 to 0.15 mmMaximum allowable projection difference between two liners . . . . . . . . 0.05 mmPiston offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 mmGrades:

Piston:A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . One file markB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Two file marksC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Three file marks

2B•2 171 and 159 engines

PistonsType . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Aluminium alloy, two compression and one oil control ring. Gudgeon

pin free in piston, interference fit in connecting rodPiston fitting direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Arrow mark on crown points to the timing gear (DT)Gudgeon pin classes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Three, colour-coded to marks on piston crownRunning clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.07 to 0.09 mm

Lubrication systemOil pressure at 4000 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5 barOil pressure switch calibration:

Operates between . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.44 and 0.58 barStops operating at . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.8 bar (maximum)

Oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion F104Oil capacity:

New or reconditioned engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2 litres (9.1 pints)After draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.0 litres (8.8 pints)Dipstick minimum to maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 litres (2.6 pints)

Torque wrench settings Nm lbf ftCam cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 7Camshaft bearing cap bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 11Camshaft sprocket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 58Camshaft stop (thrust plate) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 11Camshaft inner cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 5Exhaust manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 16Inlet manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 16Timing covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 6Mounting bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 15Cylinder head bolts:

Stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 43Stage 2 (after slackening) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 15Stage 3:

Hexagon headed bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tighten a further 120ºTorx headed bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tighten a further 300º

Timing belt tensioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 12Timing belt tensioner lock cam (interlock plunger) . . . . . . . . . . . . . . . . . 15 11Crankshaft pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 80Crankshaft main bearing cap bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 38Connecting rod big-end cap bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 35Sump bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 14Sump drain plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 33Suction drain pipe nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 4Oil pump bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 14Crankshaft front cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 12Flywheel bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 35Coolant temperature sender units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 13Engine mountings - See illustration 21.6:

A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 25B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 20C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 17D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 33E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 13F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 36G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 15

159 engineSpecification as for the type 171 engine except for the following:

GeneralStroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88.0 mmCapacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1905 ccCompression ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3:1Maximum power DIN (BHP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 at 5600 rpmMaximum torque DIN (lbf ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88.1 at 2000 rpm

ValvesHead diameter:

Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.5 mmExhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.0 mm

171 and 159 engines 2B•3

2B

Valve timingValve lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3 mmInlet opens* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -3º BTDCInlet closes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46º ABDCExhaust opens* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40º BBDCExhaust closes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2º ATDC*With valve clearance of 1.0 mm

B1A/A engineSpecification as for the type 171 engine except for the following:

GeneralCompression ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.35 to 1Maximum power DIN (BHP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 at 5600 rpmMaximum torque DIN (lbf ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97.6 at 2800 rpm

ValvesValve clearances (cold):


Valve timingInlet opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5º 6’ BTDCInlet closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23º 7’ ABDCExhaust opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35º 8’ BBDCExhaust closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0º 8’ BTDC

B2C engineSpecification as for the type 171C engine except for the following:

GeneralCompression ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.95:1Maximum power DIN (BHP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 at 6000 rpmMaximum torque DIN (lbf ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 at 3200 rpm

ValvesLength . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108.0 mmHead diameter:


BDY engineSpecification as for the type 171C engine except for the following:


D2A engineSpecification as for the type 159A engine except for the following:

GeneralMaximum power DIN (BHP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 at 5600 rpmMaximum torque DIN (lbf ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 at 3000 rpm

D2E engineSpecification as for the type 159A engine except for the following:


D2F engineSpecification as for the type 159A engine except for the following:

GeneralMaximum power DIN (BHP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 at 6000 rpmMaximum torque DIN (lbf ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122.5 at 3000 rpm


D6A engineSpecification as for the type 159A engine except for the following:




Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 mmValve clearance (cold):


Valve timingValve lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.5 mmInlet opens* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5º 9’ BTDCInlet closes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48º ABDCExhaust opens* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43º 4’ BBDCExhaust closes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1º 10’ ABDC*With valve clearance of 0.7 mm

D6D engineSpecification as for the type D6A engine except for the following:


DKZ engineSpecification as for the type D6A engine except for the following:




Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108.0 mm


2B

1 General information andprecautions

General information

171 and 159 enginesThese engines, which are fitted to the

Citroën BX 16 and BX 19 models respectively,have four wet liner cylinders, a five bearingcrankshaft and an overhead camshaft. Theengine is mounted transversely in the enginecompartment

Camshaft drive is by toothed belt. The beltis tensioned by a spring-loaded wheel andalso drives the coolant pump. The camshaftoperates directly on bucket tappets (camfollowers). Valve clearance adjustment is byshims inserted between the tappet and the

valve stem. The distributor is driven directlyfrom the tail of the camshaft.

A pressure feed lubrication system is fitted,oil being circulated round the engine by a highoutput rotary pump drawing oil from the sump.This pump is located in the bottom of the timingcase and it is driven by a chain connected to asprocket on the front of the crankshaft. Oil isdrawn through a strainer in the sump anddelivered to a filter cartridge mounted on thefront of the crankcase. A relief valve operates toprevent excessive oil pressure.

A pressure switch located directly abovethe oil filter will light the oil pressure warninglight in the instrument panel if the pressurefalls below a certain pressure. In the event ofthe cartridge filter becoming clogged, a safetybypass valve located in the filter mounting willopen to prevent oil starvation. Unfiltered oil isthen supplied to the bearing surfaces.

B1A/A and B2C enginesThese engines are used in later BX 16

models and are a development of the 171engine. All modifications are of a minornature, mainly concerning the fuel andexhaust systems.

All procedures for these engines are asdescribed for the 171 engine. Refer to therelevant text for applicable modifications.

BDY engineThis engine is used in the fuel-injected BX 16

models first introduced in late 1992. The engineis fed by a Magneti Marelli single-point injectionengine management system incorporating aclosed-loop catalytic converter.

This engine is a development of the 171engine and all procedures are as describedfor that engine. Refer to the relevant text forapplicable modifications.

D2A, D2E and D2F enginesThe D2A engine supersedes the 159A engine

used in BX 19 models for the 1987 model year.The D2A engine was itself superseded by theD2E for the 1990 model year. As part of aprocess of continual development, the D2Eengine was replaced by the D2F engine for the1991 model year. All modifications to theseengines are of a minor nature, mainlyconcerning the fuel and ignition systems.

All procedures for these engines are asdescribed for the 159A engine. Refer to therelevant text for applicable modifications.

D6A and D6D enginesThe D6A engine powers the BX 19 GTi

model and is a development of the 159Aengine. All modifications are of a minornature, mainly concerned with the cylinderhead and the fuel injection systemcomponents which replace the carburettorfitted to other BX 19 models.

The D6D engine supersedes the D6Aengine for the 1991 model year and uses aMotronic engine management system.

All procedures for these engines are asdescribed for the 159A engine. Refer to therelevant text for applicable modifications.

DKZ engineThis engine is used in the BX 19 TZi models

from March 1990, and operates in conjunctionwith a catalytic converter.

The engine is a development of the 159Aengine and all procedures are as describedfor the same. Refer to the relevant text forapplicable modifications.

PrecautionsBecause of the unusual layout of the engine

and transmission systems, extra care andattention are necessary during maintenanceand overhaul procedures which, in manyinstances, differ from more conventionalsystems.

Read through the various Sectionsconcerned before tackling any job, andanalyse the instructions, so that any snags orpossible difficulties can be noted in advance.Because the sub-assembly castings are madefrom aluminium alloy it is of utmostimportance that, where specified, allfastenings are tightened to the correct torqueand, in some instances, in the correctsequence.

2 Oil filter - removal and refitting 2Refer to Chapter 1, Section 9.

3 Major operations possiblewith engine in vehicle

The following items can be removed andrefitted with the engine in the vehicle:a) Cylinder headb) Camshaft and camshaft drivebeltc) Clutch and flywheel (after removal of

transmission)

d) Sump (after removal of the supportmember between the crossmember andthe front cross panel. Disconnect thehydraulic line from the clip attached to thesupport member)

4 Major operations requiringengine removal

The engine must be removed for thefollowing operation:a) Removal of the crankshaft and main

bearings

5 Valve clearances - checkingand adjustment 3

Refer to Chapter 1, Section 22.

6 Camshaft drivebelt - removaland refitting 3

Note: The following operation was carried outwith the engine in the vehicle.

171, 159, B1A/A, D2A, D2E andD6A engines. Also B2C, BDY,D2F, D6D and DKZ engines priorto January 1992

Removal1 Disconnect the battery earth lead.2 Remove the alternator drivebelt and HPpump drivebelt.3 Unbolt and remove the camshaft timingsprocket cover (see illustration).4 Turn the crankshaft until the dowel hole inthe pulley is at approximately 12 o’clock andthe hole in the camshaft sprocket is atapproximately 7 o’clock. In this position a 10mm dowel should pass through each hole andinto the timing recess behind (seeillustration). Verify this and then remove thedowels (see illustration).5 Remove the clutch/torque converter bottomshield. Have an assistant jam the starter ringgear while the crankshaft pulley bolt is undone.This bolt is very tight. Do not jam the pulley bymeans of the timing dowel as damage willresult. Remove the bolts and washer.6 Check that the 10 mm dowels will still enterthe timing holes. Adjust the crankshaftposition if necessary by means of the starterring gear. Remove the crankshaft pulley,retrieving the Woodruff key if it is loose. 7 Remove the timing covers from the front ofthe camshaft drivebelt (see illustration). Notethat from May 1987, a simplified three-piecetiming belt cover has been fitted. Thissimplified cover can be fitted to earliervehicles but will require the purchase of anadditional nut and screw.


6.3 Camshaft timing sprocket coverremoval

6.4a Set crankshaft pulley and camshaftsprocket dowel holes to positions

“a” and “b”6.4b Timing dowels (drills) in position

8 Slacken the two nuts on the front of thedrivebelt tensioner and the single nut at therear. Use a spanner on the square end of thetensioner cam spindle to turn the cam to thehorizontal position and so compress thetensioner spring. Tighten the cam locknut(see illustration).9 Remove the camshaft drivebelt, taking carenot to kink it or contaminate it with oil if it is tobe re-used.

Refitting10 Commence refitting by positioning thebelt on the crankshaft sprocket, then refittingthe pulley and verifying the correct position ofthe crankshaft by means of the dowel.Observe the arrows on the belt showing thedirection of rotation, and the timing lineswhich align with marks on the crankshaft andcamshaft sprockets (see illustrations). Thedrivebelt used with the type of tensionermechanism fitted to these engines shouldhave 113 teeth and white markings.11 Fit the belt to the camshaft sprocket,around the tensioner and to the coolant pumpsprocket.12 Release the tensioner cam locknut andturn the cam downwards to release thespring. Tighten the locknut and the tensionerfront nuts (see illustrations).13 Remove the timing dowels and turn thecrankshaft through two full turns in the normaldirection of rotation. Turn the crankshaftfurther to bring No 1 piston to TDC on thefiring stroke (flywheel index mark aligned withthe O-mark).14 Slacken the tensioner front nuts and thecam locknut, then retighten them to thespecified torque.15 Turn the crankshaft further and make surethat the timing dowels can still be inserted. Ifnot, remove the drivebelt and start again.16 If a new belt has been fitted, it must berun in and retensioned as follows.17 Tighten the crankshaft pulley bolt to thespecified torque, then refit and tension thealternator drivebelt and the HP drivebelt.Temporarily refit the camshaft sprocket cover.18 Run the engine up to operatingtemperature (indicated by the cooling fanoperating) then stop it and allow it to cool forat least two hours.


2B

6.7 Central timing cover removed foraccess to tensioner

6.8 Tensioner cam spindle (square end)and locknut

6.12a Turn tensioner cam downwards . . . 6.12b . . . and tighten drivebelt tensionerfront nuts

6.10b Line on belt aligns with mark oncamshaft sprocket

6.10a Timing belt-to-sprockets alignment. Arrow indicates normal direction of beltrotation

19 Rotate the crankshaft to the TDC position,No 1 cylinder firing, then slacken andretighten the tensioner nuts once more.20 Remove the alternator drivebelt, the HPdrivebelt and the crankshaft pulley. Refit andsecure the covers, then refit the pulley andtighten its bolt to the specified torque. Refitand tension the alternator drivebelt and theHP drivebelt. 21 Check the ignition timing and adjust ifnecessary.

B2C, BDY, D2F, D6D and DKZengines from January 199222 On these engines, the tensionermechanism is of an eccentric roller type.23 To accommodate this revised mechanism,a number of the surrounding enginecomponents have been changed from thosefitted to engines manufactured before January1992 (see illustration). They are as follows:a) Tensioner assemblyb) Camshaft drivebeltc) Front crankshaft oil seal carrier plated) Coolant pumpe) Right-hand engine mountingf) Cylinder block (has an extra threaded hole

for tensioner centre bolt)g) Camshaft drivebelt covers

24 Note that the type of camshaft drivebeltfitted to these engines should have 114 teethand yellow/orange markings. If the drivebelt isto be renewed, ensure that the correct type ofreplacement drivebelt is obtained.

RemovalNote: Citroën specify the use of a special tool(SEEM belt tension measuring equipment) tocorrectly set the belt tension. If this equipmentcannot be obtained, an approximate settingcan be achieved using the method describedbelow. If the method described here is used,the tension must be checked using the specialequipment at the earliest opportunity. Do notdrive the vehicle over large distances, or usehigh engine speeds, until the belt tension isknown to be correct. Refer to a Citroën dealerfor advice.25 Proceed as described in paragraphs 1 to7, noting that the crankshaft pulley timingdowel must be of 10 mm diameter, steppeddown to 8 mm at one end to engage with thesmaller hole in the timing recess.26 With the camshaft timing belt coversremoved, slacken the tensioner roller bolt torelieve the belt tension, then withdraw thebelt, noting the direction of fitting and themarkings.

Refitting27 Commence refitting by slipping the beltover the camshaft sprocket, followed by thecrankshaft sprocket, the coolant pumpsprocket, and finally over the tensioner roller.Observe the arrows on the belt indicating thedirection of rotation and the timing lines whichalign with corresponding marks on thecrankshaft and camshaft sprockets.28 With the camshaft timing dowel fitted, rotatethe tensioner roller anti-clockwise by hand as faras possible to take up any slack in the belt, thentighten the tensioner roller bolt sufficiently tohold the roller in position. If the special belttension measuring equipment is available then itshould be fitted to the front run of the belt andthe tensioner roller should be moved to give areading of 30 SEEM units. Tighten the roller boltto the specified torque, taking care not to movethe roller as the bolt is tightened.29 Check that the crankshaft and camshaftare still positioned correctly by temporarilyrefitting the crankshaft pulley and reinsertingthe timing dowel.30 Remove the timing dowels, temporarilyrefit the crankshaft pulley and turn thecrankshaft through two full turns in the normaldirection of rotation. Check that both timing


6.23 Modified timing belt and tensioner arrangement

1 Right-hand engine mounting 2 Timing belt 3 Tensioner assembly 4 Tensioner roller bolt

dowels can still be inserted. If not, remove thedrivebelt and start again. Never turn thecrankshaft backwards during this procedure.31 If all is well, remove the dowels and turnthe crankshaft through two further turns in thenormal direction of rotation.32 Refit the camshaft timing dowel andcheck that the belt can just be twisted through90º (using moderate pressure from theforefinger and thumb) at the midpoint of thelongest belt run between the camshaft andcrankshaft sprockets. If in doubt about thissetting, it is better to err on the tight side untilthe tension can be checked by a Citroëndealer. If the belt is too slack, it may jump onthe sprockets resulting in serious enginedamage. If the special belt tension measuringequipment is available, it should be refitted tothe front run of the belt. The reading shouldnow be between 42 and 46 units.33 If the tension is not as specified, repeatthe tensioning operation.34 On completion, refit all disturbedcomponents, tightening the crankshaft pulleybolt to the specified torque. Tension thealternator drivebelt and HP pump drivebelt.

7 Camshaft - removal andrefitting 3


Removal1 Remove the camshaft drivebelt.2 Remove the camshaft cover. For ease ofaccess, remove the distributor cap and HTleads also. 3 Remove the distributor and the fuel pumpfrom the thermostat housing. 4 Remove the camshaft lubrication manifold. 5 Lock the camshaft sprocket (eg. with atiming dowel) and remove the sprocketretaining bolt. Remove the sprocket. 6 Unbolt and remove the camshaft sprocketinner cover plate from the cylinder head.7 Unbolt and remove the camshaft thrustplate (see illustrations).8 The camshaft bearing caps can now beremoved, starting with bearing No 4 at the

distributor end. Make identifying marks ifnecessary then progressively loosen thebearing cap securing nuts. As the No 4bearing is removed take care not to damagethe seal between the distributor support andthe bearing. Be prepared for the camshaft tospring upwards. Remove the camshaft.

Refitting9 Commence refitting by making sure that thecrankshaft is in the correct (doweled) position.If not, move it to this position to avoidpossible piston/valve contact.10 Lubricate the camshaft bearings andlower the camshaft into position so that thefourth and sixth cams are resting on thetappets. Fit the centre bearing cap so that theoil hole is towards the front.11 Refit the remaining bearing caps andtighten them to the specified torque in aprogressive sequence. The seal bearingsurface should have sealant applied. If theseal was damaged during dismantling, renewit and coat with a sealing compound.

12 When renewing the oil seal at thecamshaft sprocket end, lubricate it withengine oil and drive it into position.13 Refit and secure the camshaft stop thrustplate.14 Check that the camshaft endfloat is asspecified and if necessary renew the thrustplate.15 Check that the valve clearances are asspecified.16 Refit the sprocket rear cover plate, locateit correctly with a 10 mm dowel and tighten itsfastenings (see illustration). Fit the camshaftsprocket, dowel it and tighten its securing boltto the specified torque. 17 Refit the fuel pump, the distributor and thelubrication manifold. 18 Refit the camshaft cover, the HT leadsand the distributor cap. 19 Refit the camshaft drivebelt.

8 Cylinder head - removal andrefitting 3


Removal1 Disconnect the battery earth lead.2 Drain the cooling system.3 Remove the air filter.4 Disconnect and plug the feed and returnhoses at the fuel pump.5 Disconnect the coolant hoses from thethermostat housing, the inlet manifold andcarburettor (heating return) (see illustrations).


2B

7.7a Undo retaining screw . . . 7.7b . . . and remove camshaft thrust plate 7.16 Locating cover plate with 10 mmdowel

8.5a Disconnect hoses indicated forcylinder head removal

5 Carburettor heating return hose6 Water outlet duct hose7 Water outlet duct hose8 Inlet manifold hose9 Heater coolant return pipe hose

8.5b Coolant hose connections tocarburettor auto-choke

6 Detach the heater coolant return hose fromits securing clamp and support lug. Unbolt thedipstick tube support bracket (seeillustrations).7 On engines manufactured before March1986, remove the engine breather supportscrew. Engines manufactured after March1986 are equipped with a modified crankcasebreather circuit (see illustration). The oilseparator unit fitted to earlier engines is nolonger fitted and the rocker cover now has abreather pipe connection.8 Disconnect the accelerator cable at thecarburettor.9 Disconnect the coolant temperature leadsand the lead from the carburettor idle cut-offsolenoid.10 Unclip and remove the distributor cap,detach the HT leads from the spark plugs andplace them out of the way. Also disconnectthe distributor LT leads. Remove the sparkplugs.

11 Detach and remove the lining from thefront right-hand wheel arch. This is bestachieved with the vehicle raised at the frontend and supported on safety stands. Theroadwheel can then be removed to improveaccess under the wing for guard removal andsubsequent operations.12 Locate a spanner onto the crankshaftpulley bolt and turn the engine over to alignthe dowel hole in the pulley with the timingrecess behind it. Insert a 10 mm dowel rod tolock the crankshaft in this position. Thepistons must be at the half stroke position intheir cylinders.13 Unbolt and detach the exhaust downpipe.14 Position a jack under the sump. Place apiece of wood between the jack and sump toprotect the sump, then raise the jack tosupport the weight of the engine.15 Remove the alternator fan guard, thenunbolt and remove the right-hand enginemounting (see illustration).

16 Unbolt and remove the upper and centraltiming covers.17 Loosen the camshaft drivebelt tensionthen disengage the belt from the camshaftsprocket.18 Remove the camshaft cover. The cylinderhead bolts can now be loosened half a turn ata time in the reverse order to that shown fortightening and then removed. Discard thebolts and obtain a new set for refitting. Notethat from February 1987, Torx type cylinderhead bolts are fitted, replacing the originalhex-head bolts. It is not necessary toretighten these bolts once the engine hasbeen warmed up to normal operatingtemperature. However, they must be renewedwhenever they are disturbed.19 Remove the cylinder head, using a coupleof bars through two of the bolt holes androcking it towards the front of the vehicle (seeillustration). Remove the gasket and recoverany loose dowels.


8.6a Heater coolant hose and support clamp 8.6b Dipstick guide tube support bracket

8.7 Modified crankcase breather circuit

P Rocker cover connection

8.15 Right-hand engine mounting

20 Fit cylinder liner clamps, or large washerssecured with nuts and bolts, to keep the linersin position (see illustration). If the liners aredisturbed, the engine will have to be removedfor new seals to be fitted.21 Before refitting the cylinder head, checkthat its mating faces are clean. Beforeremoving the liner clamps, the linerprotrusions must be checked.22 The oil filter in the cylinder head should beremoved and renewed before refitting thecylinder head (see illustration).

Refitting23 Commence refitting by fitting the dowelsto the cylinder block. Keep the flywheel enddowel raised by inserting a 5 mm punch orlarge nail through the hole in the front of theblock (see illustration). Remove the linerclamps.24 Fit the new gasket, dry and with the tab atthe flywheel end. Lower the cylinder head intoposition, making sure that it mates with thedowels. Remove the punch or nail.25 Fit the new cylinder head bolts with theirthreads cleaned and lightly oiled. Rememberto fit the spacer to the bolt above the coolantpump.26 Progressively tighten the bolts in the ordershown to the Stage 1 specified torque (seeillustration).


2B

8.23 Dowel is kept raised by inserting arod or nail beneath it

8.19 Cylinder head removal using two bars 8.20 Cylinder liners clamped with washers and bolts

8.22 Oil filter location in cylinder head (3)

8.26 Cylinder head bolt tightening sequence

Exhaust

Inlet

27 Loosen cylinder head bolt number 1, thenimmediately retighten it to the Stage 2specified torque, then tighten it further by theangle specified for Stage 3. Repeat for all thebolts, following the tightening sequence (seeillustration).28 Check the valve clearances and ifnecessary adjust them. This is applicableeven though the clearances may have beenset when the cylinder head was removed.29 Refit the timing belt and covers. Also refitthe right-hand engine mountings. Tighten allsecuring bolts to the specified torquesettings.30 Refit the remaining components in thereverse order of removal. When reconnectingthe exhaust balljoint connection, smear the tubeand bolts with Gripcott AF grease or similar.31 Refill the cooling system.32 If hexagon headed cylinder head bolts areused, start the engine and warm it up until thecooling fan cuts in, then switch off and allow itto cool for at least two hours. Loosen theengine mounting bolt indicated (seeillustration) then retighten the cylinder headbolts as described in paragraph 27. Retightenthe mounting bolt then check the valveclearances. Remember that if Torx typecylinder head bolts are fitted, retighteningafter warm-up is not required.33 If a new belt has been fitted, retension it.

9 Engine/transmission -removal 4

Note: The engine/transmission removal,separation and refitting procedures describedin this Chapter deal with the engine andmanual gearbox. If automatic transmission isfitted, the procedures are similar except forthe control linkages. Limited information wasavailable at the time of writing.

Warning: If air conditioning isfitted, the system must bedepressurised by a Specialistbefore disconnecting any

system components.1 The combined weight of the engine andtransmission is not great due to the extensiveuse of aluminium alloy, but care must betaken not to damage components. Anassistant will be required for some tasks.2 Unbolt and remove the bonnet.3 Detach the battery leads and remove thebattery. 4 Chock the rear roadwheels, then raise thevehicle at the front so that the frontroadwheels are clear of the ground. Removethe front roadwheels.5 The driveshafts must now be separatedfrom the final drive housing. On the left-handside, unbolt and release the anti-roll barconnecting link, then separate the stub axlefrom the steering balljoint. Position a draintray under the final drive housing then pull theleft-hand driveshaft and wheel hub outwardsto withdraw the inner end of the driveshaftfrom the final drive housing. About 1 litre of oilwill drain from the final drive housing as theshaft is withdrawn.6 Before removing the right-hand driveshaft,the differential sun gears must be supported inplace, if possible using Citroën special tools7101-TM and 7101-TN (see illustration). Ifthese special tools are not available, it ispossible to improvise using a suitable length of

wooden dowel or tube approximately 24 mmin diameter, chamfered at the leading end toallow entry into the side gear splines.7 The right-hand driveshaft is disconnectedfrom the differential housing by removing itcompletely.8 The hydraulic circuit must now bedepressurised.9 Remove the air cleaner unit. Also unboltand remove the air cleaner support bracket(see illustration).10 Drain the cooling system and remove theradiator.11 Disconnect the throttle cable from thecarburettor by releasing the inner cable nipplefrom the throttle quadrant then pulling theinner/outer cable from its support bracket.Place the cable out of the way.12 Disconnect the vent hose from thecarburettor (this hose runs down to theradiator left-hand lower side).13 Disconnect the fuel supply hose to thefuel pump and plug the hose.14 Note the positions of the spark plug HTleads in the location clips on the top face ofthe cam cover and release them. Detach theHT leads from the spark plugs and release thedistributor cap. Disconnect the LT leads fromthe distributor, then place the cap and leadsout of the way.


9.6 Citroën tool used to supportdifferential sun gears

9.9 Air cleaner support bracket

8.27 Home-made disc for measuring tightening angle. Disc isfixed and pointer rotates

8.32 Loosen engine mounting bolt indicated (1)

15 Disconnect the wiring harness connectionblocks under the battery support frame, alsothe wiring terminal block in line with thebattery positive lead.16 Disconnect the reversing light switchleads from the gearbox (see illustration).17 Undo the retaining nut and detach thebattery earth lead from the battery supporttray. Remove the tray.18 Disconnect the clutch cable from the leverby prising the lever rearwards.19 Disconnect the battery earth lead and thebraided earth strap from the gearbox.20 Detach the diagnostic socket leadconnector at the left-hand side under theignition coil.21 Disconnect the speedometer drive cable(see illustration).22 Disconnect the heater coolant hoses atthe bulkhead.

23 Disconnect the hydraulic suction pipefrom the HP pump and the hydraulic pumpfrom the pressure regulator outlet. Plug thepipes to prevent fluid loss and the ingress ofdirt.24 Detach the hydraulic pipe support clipfrom the alternator support strap.25 Disconnect the rigid pipe from thepressure regulator unit and detach the pipesupport clip. Position the pipe out of the way,but do not over-distort the pipe. Plug the endof the pipe.26 Disconnect the gearchange linkages atthe points indicated (see illustration). Thelinkage rods have balljoints which are simplyprised apart.27 Working from underneath the vehicle,unbolt the exhaust downpipe and disconnectit from the manifold.28 Unclip and detach the coolant bottomhose at connection on the right-hand rearlower corner of the engine. As the hose ispulled free from the connection allow foradditional coolant spillage.29 Fit the lifting sling and hoist into position.Take the weight of the engine andtransmission. Arrange the lifting sling so thatwhen connected to the lifting eyes it will allowthe gearbox to be tilted downwards at anangle of about 45º when the units are beinglifted out (see illustration).30 Working underneath the vehicle, detachthe torque link by unscrewing and removing itsthrough-bolt. If necessary position a jackunder the engine to allow it to be raised andallow the bolt to be removed (see illustration).

31 Unbolt and detach the left-hand sidetransmission mounting (see illustration).32 Unbolt and remove the right-hand upperengine mounting.33 Check around the engine/transmission toensure that all attachments are disconnected.Before lifting out the unit, it is advisable toposition a protector plate of some descriptionbetween the height corrector unit and theengine to prevent damage to the rubber dustcover during removal.34 Carefully lift the engine/transmissionupwards, tilting the transmission downwardsas the unit is manoeuvred from the enginecompartment. Assistance is necessary toguide the unit clear of its surrounding fittings(see illustration). 35 Once clear of the vehicle, theengine/transmission can be removed forcleaning and repairs as necessary.

10 Engine dismantling - generalinformation

Refer to Section 8 in Part A of this Chapter .

11 Engine dismantling - ancillaryitems

The extent of engine ancillary items to beremoved is dependent on the extent to whichthe engine is to be dismantled and repaired.


2B

9.16 Reversing light switch and leadconnections

9.21 Speedometer drive cable connectionbetween engine and bulkhead 9.26 Disconnect gear linkages at joints a,

b, c and d

9.30 Torque link and through-bolt(arrowed)

9.29 Engine lift support bracket - frontright-hand side

9.31 Left-hand side transmissionmounting

9.34 Engine and transmission removal

Refer to Section 9 in Part A of this Chapterand remove those items listed which areapplicable, ignoring references to the coolantpump and, if the cylinder head is to beremoved, the exhaust manifold. These twoitems are best removed later during theengine dismantling procedures.

Note that the clutch unit is removed afterthe engine and gearbox are separated.

12 Engine - separation fromtransmission 4

1 If still in position, unbolt and remove thestarter motor (see illustrations).2 Unbolt and remove the remainingengine-to-transmission bolts. 3 Support the engine and pull thetransmission away from it. Do not allow theweight of the transmission to hang on theprimary shaft. Recover any loose dowels.

13 Engine - complete dismantling 41 Support the engine on a clean bench orstrong table.2 Remove any remaining ancillarycomponents still attached to the engine.3 The exhaust manifold may be removednow, or it can be left in place to serve as ahandle until the head is removed.

4 Unbolt and remove the crankshaft pulley.Jam the flywheel teeth when undoing thepulley bolt to stop the crankshaft rotating.5 Remove the camshaft drivebelt covers,noting the location of the various sizes of bolt.6 Unbolt and remove the camshaft cover.7 Rotate the crankshaft by means of theflywheel until a 10 mm diameter rod can bepassed through the hole in the camshaftsprocket and into the timing recess. Thepistons are now at mid-stroke so piston/valvecontact cannot occur.8 Release the camshaft drivebelt tensioner byslackening its nuts (two at the front and onebehind the front plate) and using the squareend of the cam spindle to bring the cam into ahorizontal position.9 Remove the camshaft drivebelt, taking carenot to kink it and noting its direction of travel ifit is to be re-used.10 Unbolt and remove the camshaft drivebelttensioner.11 Remove the belt side covers and crankshaftsprocket. Recover the Woodruff key.12 Unbolt and remove the camshaftsprocket. Restrain the sprocket from turning ifnecessary using the 10 mm diameter rodinserted through the timing hole in thesprocket (see illustration).

13 Unbolt and remove the engine mountingbracket, the camshaft sprocket backplate andthe coolant pump.14 Slacken the ten cylinder head bolts,working in the reverse sequence of that usedfor tightening. Remove the bolts and washers.15 Remove the cylinder head. If it seems tobe stuck, use a couple of metal rods in two ofthe bolt holes to rock it free. Do not attempt tohammer or lever it off. Retrieve the twolocating dowels if they are loose.16 Fit liner clamps if it is not proposed toremove the pistons and liners then invert theengine.17 Unbolt and remove the flywheel. It isdoweled so it can only be refitted one way.18 Remove the suction drain pipe from theside of the sump.19 Unbolt and remove the sump. Note thelocation of the three Allen-headed bolts (seeillustration).20 Remove the bolts which secure the oilpump, noting the special centring bolt at therear.21 Unbolt and remove the oil seal carrierplate.22 Lower the oil pump into the engine so thatits chain can be removed. Withdraw the pumpand recover the spacer, the dowel and thechain (see illustration).23 Pull the oil pump sprocket off thecrankshaft and recover the Woodruff key.24 Unscrew the connecting rod cap bolts.Before removing the caps, check that they aremarked in numerical order, also theconnecting rods, liners and pistons. Markthem if they are not (see illustration).


12.1a Starter motor is secured by threeAllen bolts . . .

12.1b . . . and a mounting bracket 13.12 Lock camshaft sprocket with a 10 mm rod

13.19 Location of three Allen head bolts 13.22 Oil pump removal 13.24 Relative positions of cylinder linersand block must be marked before removal

25 If the cylinder liners are being removed,then the pistons, rods and liners can be liftedout of the block as individual units, but marktheir relative positions.26 Remove the bolts from main bearing caps1, 2, 4 and 5. Also remove the two nuts andthe two side bolts from the centre cap. Makealignment marks on the bearing caps andremove them. Keep the bearing shells withtheir caps if they are to be re-used. Recoverthe thrustwasher segments from either side ofNo 2 bearing cap.27 Remove the oil seal from the flywheel endof the crankshaft.28 Lift the crankshaft out of the crankcase.Recover the upper half main bearing shellsand the other two thrustwasher segments.29 If the cylinder liners have been leftclamped in position in the cylinder block, theirprotrusions above the cylinder block facemust be checked before reassembling theengine.

14 Engine - examination andrenovation 4

General information1 Refer to Section 12 in Part A of this Chapter.

Crankshaft and main bearings2 Refer to Section 12 in Part A of this Chapter.3 Later 171 engines (from 1984 on), incommon with 159 engines, have no spigotbush in the crankshaft tail. The diameter of the

gearbox input shaft is correspondinglyincreased.4 Therefore, on 171 engines, if the later typecrankshaft is being fitted and being mated toan earlier type input shaft, it will be necessaryto obtain and insert a spigot bush.5 If the reverse situation applies (new inputshaft and old crankshaft), extract the spigotbush.

Big-end bearings 6 Refer to Section 12 in Part A of this Chapter.

Cylinder liners, pistons, gudgeonpins and connecting rods 7 Refer to Section 12 in Part A of this Chapter.

Timing drivebelt, sprockets andtensioner8 Renew the drivebelt as a matter of courseunless it is in perfect condition and is knownto have covered only a nominal mileage.Renew the sprockets if they are damaged.9 The drivebelt tensioner should be examinedfor roughness of the wheel bearing and wearor distortion of the spring (where applicable).Renew as necessary (see illustration). Thewheel, bearing and backplate must berenewed as an assembly.

Oil pump10 Remove the six bolts which hold the twohalves of the oil pump together. Separate thehalves, being prepared for the release of therelief valve spring and plunger (seeillustration).

11 Inspect the rotors and their housing forwear and damage. No wear limits are publishedfor this pump. Any visible wear on the movingparts suggests that renewal is necessary. Withthe exception of the relief valve spring andplunger, individual components are notavailable (see illustrations).12 Lubricate the pump components wellbefore reassembly. Bolt the two halvestogether, being careful not to trap the spring.13 If the pump is to be renewed, it is wise torenew the chain and the crankshaft sprocketalso.

Camshaft and tappets14 Inspect the camshaft lobes and bearingjournals for wear and damage. If wear anddamage is evident, renewal is probablynecessary. Also inspect the bearing surfacesin the cylinder head and bearing caps.15 Clean the camshaft lubrication manifoldwith solvent and then blow through it withcompressed air. All the holes must be clear(see illustration).16 Inspect the tappets for wear and scuffingand renew as necessary. New tappets mustbe fitted if the camshaft is renewed, it is alsoadvisable to renew the valve springs.

Flywheel and starter ring gear17 Refer to Section 12 in Part A of thisChapter but ignore paragraph 49 as this isalready dealt with in this Section.

15 Cylinder head - dismantling,decarbonising, inspection andreassembly

4Dismantling1 Unbolt and remove the inlet manifold (withcarburettor) and the exhaust manifold. Renewtheir respective gaskets.2 Remove the camshaft from the cylinderhead.3 Remove the tappets and shims, identifyingtheir locations if they are to be re-used (seeillustration).4 Extract the oil filter gauze from the oilway.5 Proceed as described in Section 13 in PartA of this Chapter to remove the valves.


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14.9 Camshaft (timing) drivebelt tensionercomponents

14.10 Separating two halves of oil pump

14.11a Inspect pump gears for excessivewear

14.11b Oil pump relief valve spring andplunger

14.15 Pinholes of lubrication manifoldmust be clear

Decarbonising and inspection6 Proceed as described in Section 13 in Part Aof this Chapter and clean and inspect thevarious engine components. Note, however,that the makers state that no machining of thecylinder head surface is permitted. A warpedhead must therefore be renewed. Factoryexchange cylinder heads may have had 0.2 mmmachined off the mating face. These heads areidentified by the letter R stamped on a boss atthe distributor end of the head. A gasket 0.2mm thicker than normal must be used withsuch a head. The thicker gasket is identified bya cut-out in the tab at the clutch end.

Reassembly7 Commence reassembly of the cylinderhead by fining new valve stem oil seals intoposition, then locate the valves, the springseat washers (lubricated with clean engineoil), the springs and collets. Oil the valvestems liberally. A smear of grease will hold thecollets in position while the spring iscompressed. The valve springs can be fittedeither way up.

8 Lubricate the tappet bores. Secure eachshim to its valve stem with a dab of greaseand carefully fit the tappets. If newcomponents have been fitted so that the valveclearances are unknown, fit the thinnestpossible shims to all valves.9 Fit the camshaft to the head and oil itslobes and journals (see illustration). Fit thebearing caps, making sure that the middleones are the right way round. Progressivelytighten the bearing cap nuts to the specifiedtorque.10 Fit the camshaft thrust plate and tightenits securing bolt.11 Press the lubrication manifold intoposition (see illustration).12 Fit a new filter gauze in the oilway (seeillustration).13 Fit the coolant outlet housing, using a newgasket. Fit the thermostat and its elbow to thehousing, again with a new gasket.14 Fit the inlet and exhaust manifolds, usingnew gaskets, and tighten their fastenings tothe specified torque.15 Fit and secure the fuel pump (new gasket)

and the distributor. If alignment marks werenot made when dismantling, set thedistributor in mid-slot. The drive is offset so itcan only be fitted one way.16 Fit the carburettor and its heat insulator.17 Fit a new oil seal to the sprocket end ofthe camshaft, using a piece of tube to drive ithome.18 If valve clearance adjustment is to becarried out now, temporarily fit the camshaftsprocket and stand the cylinder head onwooden blocks so that open valves do notstrike the work surface.

16 Engine reassembly - generalinformation

Refer to Section 14 in Part A of this Chapter.

17 Engine - preparation forreassembly 3


18 Cylinder liners - checkingprotrusion 3


19 Engine - complete reassembly 4Pistons and liners1 Reassemble the piston rings to the pistonsand the pistons to the liners. Orientate thepiston rings as shown (see illustration) andarrange the oil control rings so that the railgaps are offset to each other and from thegudgeon pin hole by 20 to 30 mm.2 The piston and liner assemblies can befitted to the crankcase at this stage or, ifpreferred, after the crankshaft has been fitted.


15.9 Fit camshaft into position 15.11 Refit camshaft lubrication manifold 15.12 Insert oil filter gauze in cylinderhead oilway

15.3 Remove tappets and shims and keep in order

Crankshaft3 Position the cylinder block for access to thebottom end and fit the main bearing uppershells. Also fit the thrustwasher segments toNo 2 bearing, grooved sides outwards (seeillustration), retaining them with a smear of

grease. It will be noted that the main bearingshells supplied comprise plain and groovedtype half shells which differ according toengine type as follows:

Early engines4 On these engines there are two grooved halfshells supplied, these being fitted to the No 2and No 4 bearings on the top (crankcase) side.

Engines manufactured prior to July19865 On these engines, the bearing set containsseven grooved and three plain bearing shells,one plain bearing shell being located at thetop (crankcase) side of No 3 bearing and theother two fitted to the No 2 and No 4 bearingcaps (see illustrations).

Engines manufactured after July 19866 On these engines, there is a furtherarrangement for the location and fitting of the

bearing shells. The plain bearing shells arefitted to the bearing caps of Nos 2 to 5bearings inclusive. The No 1 bearing cap andupper half-shells are all grooved (seeillustration). The bearing shell location lugrecesses in the crankcase are changed to suitthe new bearings. Earlier and later-type shellbearings are thus not compatible. Whenordering replacement bearing shells, it istherefore important to be specific on whichtype is required.

Engines manufactured after July 19877 As from this date, grooved shells are usedin the crankcase seats, and plain shells in thebearing caps.

All engine types8 Oil the bearing shells and lower thecrankshaft into position, taking care not todislodge the thrustwasher segments (seeillustration). Inject some clean engine oil intothe crankshaft oilways.9 Check the crankshaft endfloat by pushing itin one direction then the other along itslength. A dial gauge or feeler blades should beused to measure the endfloat. If the endfloatmeasured is not within the specified limitschange the thrustwasher segments and fitalternatives of suitable thickness.Thrustwashers are available in a choice of fivethicknesses.10 Fit new side seals to No 1 main bearingcap. Carefully fit the cap with its bearing shell.Using clean engine oil, lubricate the shell, thesides of the cap and the locating surfaces inthe block. There is a risk of displacing or


2B

19.1 Fitting direction for standard pistonrings

19.3 Fitting thrustwasher upper segments

19.5a Main bearing cap fitting positions - early type

L Plain bearing half shell positions

19.5b Main bearing cap fitting positions - later type

L Plain bearing half shell positions

distorting the side seals as the cap is fitted, soprotect them with a couple of feeler blades orthin strips of tin which can be withdrawnrearwards after fitting the cap (seeillustrations).11 Fit the shells to the other main bearingcaps, lubricate them and fit the caps. Fit the

thrustwasher segments (grooved sideoutwards) to No 2 cap. Observe the matingmarks made when dismantling. The lug oneach bearing cap points towards the timingsprockets. Ensure that the thrustwashersegment on each side of the No 2 mainbearing cap is of equal thickness to the

corresponding upper segment washerselected when setting the crankshaft endfloat.12 Fit the main bearing cap nuts and boltsand tighten them to the specified torque.Tighten the side bolts on No 3 cap last (seeillustration).13 Check the protrusion of No 1 cap sideseals above the sump mating face, this shouldbe 2 mm. Trim off any excess.14 Recheck the crankshaft endfloat andensure that it rotates freely.15 Fit a new oil seal (lips inwards andlubricated) to the flywheel end of thecrankshaft. Drive it into place with a piece oftube (see illustration).16 If not already fitted, fit new O-ring seals tothe cylinder liners, then fit the pistons andliners (see illustration).17 Reconnect the connecting rod big-endsto the crankshaft.

Oil pump18 Fit the Woodruff key and oil pump drivesprocket to the crankshaft nose. Fit the chainover the sprocket (see illustrations).19 Make sure that the locating dowel is inposition, then engage the oil pump sprocketin the chain and offer the pump to the block.Engage the pump on the dowel, then lift it upfar enough to slide the L-shaped spacer inunderneath it (see illustrations).20 Fit the oil pump securing bolts,remembering that the special centring bolt isnearest the flywheel, and tighten them to the


19.8 Fitting the crankshaft 19.10a Fitting a side seal to No 1 mainbearing

19.12 Tightening No. 3 main bearing sidebolt

19.15 Crankshaft oil seal - flywheel end 19.16 Arrow mark on piston crowns mustpoint to camshaft sprocket end (letter and

number indicate liner and gudgeon pin grade)

19.10b Protecting side seals with feelerblades

19.6 Main bearing shell locations - BX 16 and BX 19 from July 1986

L Plain shells in caps

specified torque. Generously lubricate thepump and the chain with clean engine oil (seeillustration).21 Refit the pulley oil seal carrier plate, usingsilicone jointing compound on the blockmating faces. Fit a new oil seal, lubricated lipsinwards, and drive it home with a piece oftube.22 Fit the sump, using a new gasket, andtighten its securing bolts progressively to thespecified torque. Remember the correctlocation of the three Allen-headed bolts.23 Refit the suction drain pipe, using a newO-ring. Do not overtighten the securing nuts,refer to the Specifications for the correcttorque setting.

Flywheel and clutch24 Fit the flywheel to the crankshaft flangeand secure with new bolts, using threadlocking compound. Tighten the boltsprogressively to the specified torque.25 Fit the clutch friction plate and pressureplate.

Cylinder head26 Position the engine for access to thecylinder head face. Rotate the crankshaft tobring the pistons to mid-stroke (none at TDC),then remove the liner clamps.

27 Check that the head mating surface isclean and that the two locating dowels arepresent. Place a 5 mm diameter rod in thehole beneath the dowel at the flywheel end tostop the dowel being displaced downwards.28 Fit a new cylinder head gasket, dry andwith the protruding tab at the flywheel end(see illustration).29 Lower the assembled cylinder head intoposition, making sure that it engages with thedowels.30 Fit the cylinder head bolts, with theirthreads clean and lightly oiled. Remember tofit the spacer to the bolt above the coolantpump. 31 Tighten the cylinder head bolts pro-gressively in the order shown in illustration8.26 to the Stage 1 specified torque.32 Slacken cylinder head bolt number 1, thenimmediately retighten it to the Stage 2specified torque, then tighten it furtherthrough the angle specified for Stage 3.Repeat this operation on the other bolts insequence.

Camshaft drivebelt33 Fit the camshaft sprocket backplate,using a 10 mm rod through the timing hole tolocate it precisely before tightening itssecuring bolts.

34 Fit the camshaft sprocket, washer andbolt. Use the 10 mm rod to lock the sprocketin the correct position and tighten the bolt tothe specified torque. Remove the rod.35 Fit and secure the coolant pump, using anew gasket. Tighten the bolts to the specifiedtorque.36 Fit the covers around the coolant pump,noting the locations of the various specialbolts (see illustration). Smear the large boltthreads with sealant.37 Fit the Woodruff key and the crankshaftsprocket.38 Fit the camshaft drivebelt tensioner butleave the nuts slack. Compress the spring bylocking the cam in the horizontal position.


2B

19.19a Fitting oil pump - chain must beengaged first

19.18a Fitting oil pump drive sprocket 19.18b Oil pump drive chain

19.19b Locating oil pump spacer

19.20 Special bolt location 19.28 Head gasket correctly fitted

39 Temporarily fit the crankshaft pulley, itswasher and bolt. Lightly tighten the bolt.Carefully turn the crankshaft until a 10 mm rodwill pass through the timing hole in the pulleyand into the timing recess. If piston/valvecontact occurs, back off and try again withthe camshaft in a slightly different position. Donot try to force the crankshaft if a pistoncontacts a valve.40 Use the 10 mm rod to position thecamshaft sprocket, then remove the crankshaftpulley and fit the camshaft drivebelt. Be carefulnot to kink the belt as it is fitted and observethe arrows showing the correct direction ofrotation. The stripes on the belt should align

with the timing marks on the sprockets.41 Withdraw the timing rod. Tension the beltby turning the tensioner cam so that it pointsdownwards and secure it with its locknut.Tighten the two nuts at the front of thetensioner.42 Turn the crankshaft through two full turnsin the normal direction of rotation. Rotate itfurther to bring Nos 1 and 4 pistons to TDCwith the valves on No 1 cylinder open.43 Slacken the two nuts and the cam locknuton the drivebelt tensioner, then retighten them.44 Temporarily refit the crankshaft pulley,rotate the crankshaft and check that thetiming rods can be inserted simultaneously in

the crankshaft pulley and camshaft sprocketholes. If not, remove the belt and try again.Remove the pulley.45 Fit the engine mounting bracket andtighten its bolts.46 Refit the drivebelt covers, but note thatthey will have to be removed later to retensionthe drivebelt if a new one has been fitted.47 Fit the crankshaft pulley, washer and bolt,making sure that the Woodruff key is still inposition. Jam the starter ring gear teeth andtighten the bolt to the specified torque.48 Refit the camshaft cover, noting thecopper washer at the sprocket end bolt andusing a new gasket.


19.36 Drivebelt cover special boltlocations

E Use thread sealant

Ancillary components49 Refit the ancillary components listedbelow. It may be preferable to leave delicateitems such as the alternator and distributoruntil after the engine is refitted:a) Oil filler/breather pipeb) Oil pressure switch c) Coolant inlet housing and pipe (see

illustration)d) Spark plugs, distributor and HT leads e) HP pump and drivebelt (see illustration)f) Alternator and drivebelt

50 Fit a new oil filter with its sealing ring welllubricated. Tighten by hand only.

20 Engine - reconnection totransmission 4

1 Check that the clutch release componentsare correctly fitted in the gearbox and that thepressure plate and friction disc are fitted tothe flywheel. On automatic transmissionmodels, check that the torque converter isproperly located.2 Smear a little anti-seize compound on thenose and splines of the transmission primary(input) shaft, then offer the transmission to theengine. Do not allow the weight of thetransmission to hang on the input shaft. If theinput shaft does not wish to pass the clutch, itis possible that the clutch disc is not centred.Check also that the transmission input shaft iscompatible with the spigot recess in thecrankshaft.3 Engage the engine-to-transmission dowelsand loosely fit the bolts. Also fit the starter

motor, which is secured by three Allen boltsand a bracket.4 On manual gearbox models, fit the clutchcable guide and pivot brackets.

21 Engine/transmission -refitting 4

1 Arrange the lift sling so that the gearboxtilts down at an angle of 45º when theengine/transmission is raised.2 An assistant should be at hand to guide theunit into position as it is lowered. Take carenot to damage any associated componentswithin the engine compartment, the hydrauliclines in particular. The suspension heightcorrector control unit can be protected frompossible damage by shielding it with asuitable piece of sheet metal. Also, beforelowering the combined units into position,

check that the gearchange return levers areset parallel to the steering gear unit.3 Carefully lower the engine/transmission intothe engine compartment, guiding the gearboxdown forwards of the battery tray support.When clear of the support, swivel the gearboxrearwards then raise it so that the mountingstud enters the mounting slot. Locate themounting rubber (cone face upwards), then fitthe flat washer and nut. Do not fully tighten itat this stage.4 Further lower the lifting hoist to guide theengine down so that it engages with theright-hand mounting and its torque link(underneath towards the rear).5 Locate a plain nut and washer to secure theright-hand mounting and insert thethrough-bolt and fit the self-locking nut tosecure the torque link.6 Tighten the mounting nuts and the torquelink nut and bolt to their specified torquesettings (see illustration).


2B

19.49a Securing coolant pipe to inlethousing

19.49b Refitting HP pump and drivebelt

21.6 Engine mountings

Inset top Right-hand mounting up to July 1983Inset bottom Right-hand mounting from July 1983

7 Reconnect the following items, referringwhere necessary to the relevant Section orChapter for further details:a) The gearchange link rodsb) The speedometer cablec) The coolant hoses to the coolant manifold

located between the cylinder head andthe bulkhead

d) Fuel feed and return hosese) The HP pump unit hoses. Retighten the

regulator bleed screwf) Accelerator cable to the carburettorg) Wiring harnessesh) Clutch cable to release arm. Lubricate the

pushrod with grease at each end beforeassembling

i) Exhaust downpipej) Radiator and coolant hosesk) Braided earth straps to the gearbox,

battery support tray and battery8 When refitting the alternator guard, pressthe retaining grommet into the right-handengine mounting bracket as shown using arod and pliers (see illustration). Take care notto pierce the bottom end of the grommet andsmear it with a little soapy solution to easefitting.

9 The driveshafts and associated steering/suspension components should be refitted inaccordance with the instructions given in theappropriate Chapter. Refit the right-handdrive shaft first.10 Before refitting the air filter and air ducts,check around the engine/transmission toensure that all fittings are securely andcorrectly made. 11 Top-up and bleed the cooling system.12 Top-up the engine oil level, having checked

that the sump plug is securely fitted.13 Top-up the gearbox oil level with thespecified quantity of oil. Note that the gearboxfiller plug is not a level plug.

22 Engine - initial start-up afteroverhaul 3

1 Follow the check procedures described inparagraphs 1 to 7 inclusive in Section 19 inPart A of this Chapter.2 If hexagon headed cylinder head bolts arefitted, allow the engine to cool for at least twohours. Loosen the bolt which secures theengine right-hand mounting bracket to theblock, then retighten the cylinder head boltsas described in Section 8. Tighten themounting bracket bolt on completion. Nosubsequent retightening is necessary. Notethat where Torx type cylinder head bolts arefitted, retightening after warm-up is notrequired. 3 Recheck the valve clearances. 4 If a new camshaft drivebelt was fitted thenretension it.


21.8 Method devised for securingalternator guard retaining grommet

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