My First Rebuild Of The Xu Engine

[jord294 92]

hello everyone

 

i'm very familiar with changing head gasket, cambelt etc. but have decided to have a go at a rebuild of an xu engine.

 

i have stripped most of the bottom end (already done top end) but a couple of things i am uncertain of, and would appreciate some help.

 

firstly. is the smaller gear which is on crankshaft, supposed to spin freely?

 

 

secondly. i have found that the shells in no.1 con-rod have spun, leaving slight scoring on the cap. if i sand it smooth, will that be ok when new shells are fitted

 

 

 

and thirdly. i found the following inside the sump when i removed it. is it supposed to be there? or is it part of the bottom end components

 

 

thanks

Edited April 9, 2008 by jord294

[Tom Fenton 1,542]

The small gear on the crank tail drives the oil pump, when the bottom pulley bolt is torqued up this compresses against this gear to give drive. Not the nicest design feature IMO! If the crank pulley bolt comes loose you lose drive to the oil pump!

 

If a shell has spun in a rod this generally will have scored the rod meaning it is no longer the right size to accept the bearing shells. A good machine shop can sometimes reclaim the rod by skimming material from the cap and the rod, then bolting them back and re-boring and honing the hole for the bearing. Alternatively you can source another rod. For a XU Peugeot engine for which parts are easy to get I'd probably get another (set) of rods. Probably worth checking the rods for balance if swapping a single one in from another set.

So in summary, no you can't sand it and re-use it (well, I wouldn't personally anyway).

 

Not sure what it is in No3, have you a clearer picture? Looks like a roll pin?

[Doof 11]

Is it the roll pin to hold the trapdoor into the sump baffle? providing its an xu10?

[jord294 92]

it is a roll pin. but it's just a standard xu9 engine

 

it was just strange to find it in the sump

 

i have found that the shells for no.3 a quite bad also. the shells are very copper coloured. the crankshaft itself looks to be in good condition

 

the liner bores also seem to be in good condition. just a honing should sort them. was thinking of fitting new rings to the existing pistons, but as mentioned, i should look into getting a new set of con-rods

 

does anyone know the going rate for

 

1, new con-rods

2, new set of rings

3, maybe a crank regrind

 

one other thing. when the xus have the oil starvation. is it only the con-rod shells that pick up, or do the crankshaft shells pick up aswell? if you understand what i mean?

 

thanks

[Tom Fenton 1,542]

If it has spun a shell then having the crank checked and polished is a must in my book.

[mojo1997 0]

does anyone know the going rate for

 

2, new set of rings

 

 

£32.75+ vat for the big end bearings from Main Dealer......Not sure about price for other stuff...

[HERMAN 33]

Hello mate just duing the same job my self. I have got all the bits together head set, conversion set new shells and thrust bearings. Getting ready to put it all back togther and I throught that I would replace the liner seals. This is were it all went wrong. The liners are baddly corroded and so is the block. Take me advice and pull the liners out before you buy any parts.

Also if I can not find another block with good liners I will have a load of parts to sell so I will keep you informed.

[jord294 92]

Hello mate just duing the same job my self. I have got all the bits together head set, conversion set new shells and thrust bearings. Getting ready to put it all back togther and I throught that I would replace the liner seals. This is were it all went wrong. The liners are baddly corroded and so is the block. Take me advice and pull the liners out before you buy any parts.

Also if I can not find another block with good liners I will have a load of parts to sell so I will keep you informed.

 

to be fair, the liners are in very good condition, as are the pistons. no corrosion at all between outside of liner and wall of block.

 

cheers

[jord294 92]

here is an update, of what else i have found.

 

question first.

 

are the caps for the conrods supposed to be fastened on the same way? (with cutouts on rod and cap the same side?) coz i found that no.3 cap was different to other 3

 

 

here's a pic of 4 and 3 pistons

 

 

here's a pic of 1 and 2 pistons

 

 

also no.2 shells seem to be the only ones that sit perfectly in both rod and cap. all the other shells seem to have shrunk. not sure if you can make it out in picture?

 

 

i believe this is because engine has got very, very hot.

 

i have been quoted £12 per journal for crank regrind. forgot to ask about conrod resizing though.

 

should i take all 4 conrods and pistons complete, and get the machine shop to remove the gudgeon pins ?

Edited April 11, 2008 by jord294