Newbie does a Xantia 1.9TD Head Swap - ho ho ho!

Xaccers · Unread post by **Xaccers** » 11 Sep 2009, 22:28

Jim and I used the new bolts to line everything up rather than chop up the old ones and get them stuck in (Murphy's law and all that)

MikeT · Unread post by **MikeT** » 12 Sep 2009, 10:12

Sounds like you've got it all under control but you didn't mention the gasket thickness. You're aware how important it is, right?

MikeM · Unread post by **MikeM** » 12 Sep 2009, 17:03

MikeT

Sounds like you've got it all under control but you didn't mention the gasket thickness. You're aware how important it is, right?

Yeah. The one that came off had three notches so that's what I got to replace it.

MikeM

MikeM · Unread post by **MikeM** » 12 Sep 2009, 17:08

Xac, MikeT and anyone else in the know..

The head bolts I bought turned out to be shorter than the originals by exactly the length of the spacers - implying that they can be used but without the spacers (obviously). Just wondering if you guys came across this and whether you had any problems fitting shorter ones. I'm a bit scared that the shorter bolts have less material to stretch under that much tension and maybe the spacers are there to absorb some of it by compressing.

Tempted to buy another set same length as originals.

Mike

MikeM · Unread post by **MikeM** » 12 Sep 2009, 17:53

Well as planned I got the camshaft front oil seal fitted once I found a 36mm socket to use as a drift and the sprocket went on soon after.

Noticed something was missing and thought now might be a good time to fit the vacuum pump to the other end of said shaft.

Made sure everything was clean and fitted the gasket noting it's tendancy to move. Then remembered that I hadn't chased out the head bolt threads in the block so off with the gasket, do that, clean up again .. .. ..

I inserted a head bolt in the No 10 hole of the head and working from the drivers wing gently lowered the head feeding the protruding bolt through the gasket as planned - I really don't get why the BoL suggests all that bolt cutting malarky

Okay maybe this'll come back to bite me in the asp - we'll see.

This is where I noticed that the new head bolts I purchase on eBay (with the head gasket I refused to fit) were significantly shorter than the originals - and not just due to stretching - these are shorter by exactly the length of the spacers. This has me worried that I may shear them while torquing down as simple physics tells me that you can't stretch a short bolt the same amount as a longer one made of the same material.

So, waiting for feedback from others who have travelled this road, my current position is to use these to hold the head in place until I get either reassurance that all is well or a new set of bolts but a bit longer.

The next step was to try fitting the exhaust manfold to the head, but again the crappy (can I say that here?) gasket that came in the head set started to break up as soon as the manifold nudged it. Gotta get me an all metal one like I saw on MikeT's photos.

So. Some progress today but since here in rural Norfolk I can't get the bits I need until Monday morning...

... I guess it's beer o'clock.. Why don't ya join me.

Mike

Xaccers · Unread post by **Xaccers** » 12 Sep 2009, 21:00

I'm pretty sure the new bolts were nearly as long as the old ones Mike, sounds like you may have been given the wrong set.

MikeM · Unread post by **MikeM** » 12 Sep 2009, 21:21

Xac wrote:I'm pretty sure the new bolts were nearly as long as the old ones Mike, sounds like you may have been given the wrong set.

Seems that way Xac. I've been in touch with my supplier this evening (I guess somebody doesn't like X factor) and they've held their hands up to it. New bolts on way on Monday. Kinda slows me down though

MikeM

MikeT · Unread post by **MikeT** » 13 Sep 2009, 08:47

I think my old gasket had three notches but as my head was skimmed, I fitted the thickest gasket I could find which I believe is also known as a repair gasket and I think it had 8 notches.

Anyway, this delay might be a blessing in disguise, take a read of this
http://www.google.co.uk/url?sa=t&source ... 6MlhcsmOQw

And then check this
www.ajusa.es/eng/noticias/data/upimages/36i.pdf

MikeM · Unread post by **MikeM** » 13 Sep 2009, 10:38

MikeT,

Thanks for that. I was just about to go off and refit the timing bits. Think I'll lift the head back up and check to see just what thickness gasket I really do have.

MikeM

MikeT · Unread post by **MikeT** » 13 Sep 2009, 16:47

I think the notches part is intentionally left sticking out so you won't need to lift the head, touch wood?

MikeM · Unread post by **MikeM** » 13 Sep 2009, 17:34

MikeT wrote:I think the notches part is intentionally left sticking out so you won't need to lift the head, touch wood?

Affirm on that. Got three notches, but was wondering if that link to Ajusa gaskets was specific to them or whether the whole industry has adopted the new system. Don't think it matters too much as I expect compression on a 200k engine to be down a bit anyway. I've now managed to refit the timing gear and belt (old one for now to test procedure) and rotated engine successfully by hand with no sign of valve/piston contact - will try again once the new bolts arrive and I can torque it down properly.

Did have a "oh no WTF" moment though. Rotating the engine by hand it would only move about 30 degrees of the crankshaft in either direction. Checked camshaft to see which valves were being depressed but then realised that pistons 1 and 4 would be on there way down and 2 and 3 were still near BDC - huh

- Ooops, try taking car out of gear/releasing hand brake - Doh!

MikeM · Unread post by **MikeM** » 13 Sep 2009, 17:58

And then check this
www.ajusa.es/eng/noticias/data/upimages/36i.pdf

Just been back to this info and had a re-read.

Worst case - It looks like I've got a new system 3 notch when maybe it ought to be a five notch. Crunched some numbers...

The difference is less than 0.1mm of thickness, so using 0.1mm and the bore/stroke and comp ratio according BoL and by my reckoning the compression ratio may be increased by as much as 0.55 to 22.35:1

I'll supply my working out if anyone wants it but right now it's time to get a cider inside me.

Mike[/quote]

MikeM · Unread post by **MikeM** » 14 Sep 2009, 08:45

To one and all...

I've just read in BoL about injector 'sleeves'. Never heard of them before and don't remember seeing any in the old head (will check later today).

Anyone else found these to be missing ?

Any advice welcome.

Tks
MikeM

Unread post by **CitroJim** » 14 Sep 2009, 10:26

MikeM wrote:I've just read in BoL about injector 'sleeves'. Never heard of them before and don't remember seeing any in the old head (will check later today).

Hi Mike, great blog

Good work!

The sleeves the BoL refers to are part and parcel of the injector and generally never need replacing when doing a head job. The only time they would be replaced is if the injectors themselves are being rebuilt.

What is important is to replace the domed firewashers, making sure they are up the right way round (dome facing up) and the copper washers. These both should be included in the gasket set.

MikeM · Unread post by **MikeM** » 14 Sep 2009, 12:16

Hi Jim,

Nice to e-meet you.

Thanks for that. I was starting to think I'd overlooked them or that someone else had replaced the injectors previously without them.

I've had the injectors refurbed professionally so I've got all new copper and fire washers coming out of my ears at the mo'.

Hoping for a tail wind this afternoon as I've been out buying bits again this morning and lost precious time.

Cheers,

MikeM

French Car Forum

Newbie does a Xantia 1.9TD Head Swap - ho ho ho!

Head bolts - length

Daily progress (if that's the word)

Bolts

Gasket thickness - thank heavens it's straight forward

Notches

Help Please - Injector Sleeves ???

Re: Help Please - Injector Sleeves ???

Sleeves ....