1.9 and 2.1 liter XUD diesel engines
All engines are four-cylinder and have an injection system in the prechamber or in the distribution manifold. 1.9L engine (XUD9) or XUD11 is installed in the engine compartment perpendicular to the movement. There are several types of 1.9 liter engines:
XUD9TF/L engine (D8B)
This engine is equipped with a turbocharger and an exhaust gas recirculation system. Its power is 67.5 kW at 4000 rpm. A Bosch injection system was installed, as well as a distribution type injection pump.
Engine XUD9TF/Y (DHX)
This engine is equipped with a turbocharger and an exhaust gas recirculation system, as well as an oxidation type catalyst, and has a power of 66 kW at 4000 rpm. A Bosch injection system was installed, as well as a distribution type injection pump.
Engine XUD11BTE/L3
This engine has a displacement of 2088 cm3 and power 110 hp (80 kW) and the designation XUDl IBTE. L3 - indicates the degree of neutralization of the exhaust gas. This engine has three valves per cylinder and is equipped with an EPIC fuel injection system developed by Lucas. The engine valve clearance is adjusted automatically by installed hydraulic tappets.
The cylinder block is cast from gray cast iron, and the cylinder head is made from a light metal alloy. The engine has a single camshaft which is driven by a toothed belt from the crankshaft. The cylinder head is drilled for valve seat rings, valve guides, and also for pre-chambers for fuel injection.
Removing the engine
Despite some differences inherent in different types of engines, the work of removing and installing the engine is considered as a whole.
The power unit is removed from the engine compartment using a hoist, beam or crane. In workshops, when removing the power unit, they also use a lift on which the engine is lowered. To remove the engine in front of the car, it is necessary to install it on the goats and dismantle the elements of the front end. Depending on the car model, minor features of engine dismantling are possible, however, in general, the procedure for removing the engine is as follows.
1. Remove wheel covers.
2. Apply the parking brake and loosen the front wheel hub nuts (see illustration 2.2). Do not completely loosen the nuts. The vehicle must be on wheels
3. Disconnect both terminals from the battery terminals.
4. Drain coolant and, if necessary, transmission fluid.
5. Remove the front lining (see illustration 2.5).
6. Remove the air filter.
7. Remove the grille along with the radiator fan and the radiator itself (see illustration 2.7).
Car manufacturers are increasingly using special hose connections and for this reason it may be that the lower radiator hose is connected in this way. The procedure for removing a hose with such a connection is indicated in the relevant chapter (see «Cooling system»). Therefore, if necessary, read the provisions of this chapter. The heater hoses can also be connected in a special way.
8. Remove the locking clip of this connection first. After that, use a screwdriver to press the leash to the right and at the same time disconnect both hoses in turn (see illustrations 2.8 and 2.8a).
9. Remove the boost air cooler (intercooler). If the car has air conditioning, then release the compressor and evaporator, and then remove them (see illustration 2.9). Do not open the air conditioning system. First loosen the evaporator, heat shields and compressor, and then remove them.
10. Detach the frame cross member (see illustration 2.10).
11. Turn out bolts of fastening and remove the pump and a reservoir of the hydraulic booster of a steering (see illustration 2.10).
Attention! Do not open the power steering system. Be careful not to get power steering fluid on the paintwork.
12. Remove the ABS control unit located on the left side of the engine compartment (see illustration 2.10).
13. Disconnect all hoses, wires and pipelines connected to the power unit. Before that, mark them for later installation.
14. Turn out bolts of fastening of wheels.
15. Install in front of the car on the goats.
16. Disconnect from a transmission the mechanism of a gear change, acting from under the car. At the same time, disconnect the flexible shaft of the speedometer from the gearbox, remove the clamp that secures the front pipe to the body.
17. Disconnect and remove the following parts:
- expansion tank for coolant;
- switching valve for the exhaust gas recirculation system;
- heater hoses secured with a special connection (see illustration).
16.17 Disconnect and remove the following parts:
1 - expansion tank for coolant
2 - EGR switching valve
3 - heater hoses
18. Disconnect the wheel drive axles (see relevant chapter).
19. Turn out bolts 2 and 5 (see illustration 2.19) and remove bracket 3 of the front engine mount.
20. Disconnect all wires from the gearbox (starter wire and reversing light switch wire).
21. Attach the hooks of a hoist or other lifting device to the engine lugs and raise the power unit slightly.
22. Release the supports of the right and left engine and gearbox mounts. To do this, it is enough to disconnect the brackets, and the support pads remain fixed to the body (see illustration 2.22).
23. Make sure everything attached to the engine is disconnected. After that, lift the power unit and remove it from the engine compartment. The power unit must be removed from the engine compartment at a certain angle and therefore it should be deployed. Make sure that the power unit does not snag any wires or pipes.
24. Place the power unit on suitable supports, such as wooden beams, and secure it from tipping over.
25. Inspect the power block and make sure that it has no external damage or places with oil or coolant leaks.
26. Clean the engine surface. When doing so, cover any parts that could be damaged during cleaning.
Installation
The installation of the power unit is carried out in the reverse order of removal.