Berlingo XUD9TE project (Y THO?)

[dollywobbler]

What's the latest with this one or is it a bad idea to ask?

[Lacquer Peel]

It's stalled a little because I'm lazy and it's outside.
I started on the work it needs for the MOT last weekend, new CV boot, balljoints, pinch bolts and wishbone bushes. I thought it just needed the 'P' bushes but the round bushes on the nearside are gubbed as well.
I measured up the exhaust and bought a section of reducing pipe to join the Xsara front pipe to the Berlingo middle section.
The air intake needs rerouted, the loom tidied up and bits of XUD loom attached.
The rev counter, oil level and speedo plugs look similar but don't match. Cheers PSA!
The glow plugs don't work off the ignition, I'm not sure why not.
I finally have the pulley to go with the Bosch pump but not sure I can be arsed fitting it immediately. I bought a Lucas stop solenoid so I can use the Prince of Darkness in the meantime.
A long list but it's all fairly straightforward.

[twosmoke300]

"Just put an xud in - straight swap they are "

 

Are they fuck ! Like all engine swaps

[alcyonecorporation]

 

It's stalled a little because I'm lazy and it's outside.

I started on the work it needs for the MOT last weekend, new CV boot, balljoints, pinch bolts and wishbone bushes. I thought it just needed the 'P' bushes but the round bushes on the nearside are gubbed as well.

I measured up the exhaust and bought a section of reducing pipe to join the Xsara front pipe to the Berlingo middle section.

The air intake needs rerouted, the loom tidied up and bits of XUD loom attached.

The rev counter, oil level and speedo plugs look similar but don't match. Cheers PSA!

The glow plugs don't work off the ignition, I'm not sure why not.

I finally have the pulley to go with the Bosch pump but not sure I can be arsed fitting it immediately. I bought a Lucas stop solenoid so I can use the Prince of Darkness in the meantime.

A long list but it's all fairly straightforward.

Have you nominated this shot for the 2018 calendar?

[Lacquer Peel]

"Just put an xud in - straight swap they are "

 

Are they fuck ! Like all engine swaps

 

Aye. I think with experience and less conflicting advice online it could be done over a weekend. It isn't plug and play, that's for sure.

 

 

Have you nominated this shot for the 2018 calendar?

 

Non. It will look grainy as fuck embiggened, my camera phone is noisy.

[twosmoke300]

If it makes you feel any better my experience shows that all engine swaps are the same .,I've had stuff with the same engine code out of the same year car have different mounts , manifolds and even dipsticks .

Favourite was a little punto 8v where even the cam spkt was different and rubbed the head !

[Lacquer Peel]

 

Bosch pump fitted*.

Apart from the much improved vegability and tuneability it looks a lot cooler than the Lucas pump.

[Lacquer Peel]

Trying to get the cambelt back on but it seems like there's not enough slack to pull the belt back on to the pulleys. Normal or just me being a fud?

[Sigmund Fraud]

Trying to get the cambelt back on but it seems like there's not enough slack to pull the belt back on to the pulleys. Normal or just me being a fud?

 

Do the Lucas and Bosch engines use the same belt ? I'd check with the Gates catalogue...

[Lacquer Peel]

Same belt

[Sigmund Fraud]

In that case : Is the tensioner fully undone ? Is there a specific installation sequence (crank pulley is often last ?).

[Lacquer Peel]

It's right at the back of its travel. I think you need three hands to do it. The timing belt isn't fully off, just the IP and cam pulleys.

[Lacquer Peel]

I've worked it out. The tool I was using to move the tensioner (a 1/4 to 3/8 adapter) was pulling the belt back with it. I might have to buy a shitty Rolson socket set at the garage just for a 3/8 extension

[Lacquer Peel]

It's still not going on. WTF BBQ.

[Dave_Q]

Could it have moved a tooth on the crank pulley while it was loose? The cam-pump-crank side needs to be supa tight to make slack on the other side.

 

Otherwise maybe try removing the tensioner completely, then putting the belt on, then the tensioner.

[Lacquer Peel]

Possibly, I did manipulate the belt a little. I'll try manipulating it a bit more

[Lacquer Peel]

If it's jumped a tooth at the crank end do I need to undo the bottom end and refit the belt?

Will the crank pulley come off okay with an allen key locking the flywheel?

[Lacquer Peel]

And if I remove the tensioner won't that make getting it back on a 'mare?

I have a knack of turning relatively straightforward jobs into long winded missions.

[Richard]

Don't remove the tensioner if you can help it, I had enough bother fitting it with the engine out.

[Sigmund Fraud]

French cars have a knack of turning relatively straightforward jobs into long winded missions.

 

EFA

[Lacquer Peel]

It's on now

[Sigmund Fraud]

[Guest Hooli]

Looks like the product of eastern european drivers, as stored in laybys everywhere.

[Lacquer Peel]

Bleh.

It turns over but the engine just 'coughs', I guess a dry pump and injectors take a while to prime and bleed.

[dollywobbler]

Oh dear. Is there not a bleed pump? Was chuffed to bits once I found the one on the ZX. That wasn't keen on starting after just a filter change.

[Dave_Q]

There is normally a hand primer on these but that only gets you as far as the pump.

 

To bleed one of these up I would:

 

Crack off the outlet on the pump

Pump the hand bleeder until fuel comes out - close outlet

Crack the injectors, one at a time, and turn the engine over a bit to check there's fuel

Crank away like a bastard till it eventually catches. 

 

 

Note: the last step is not recommended by Haynes manuals or those with mechanical sympathy, crank for 20-30 seconds max at a time before  stopping for 1 min to cool things down.

[Lacquer Peel]

There is a primer bulb and I have been using it but there are a few variables like the fuel screw not being at the standard setting and I don't know if the pump timing is right, but I believe it'll start as long as the timing isn't wildly out.

[Rusty_Rocket]

Best way imo is to put a clear, clean piece of pipe on the pump outlet.

Suck on the pipe until diesel comes through. That way you know the pump, filter and lines are as full and air free as possible.

[Lacquer Peel]

Richard is up this way with work and we got it going again despite my best* efforts (slamming the bonnet down with the bonnet cable improperly routed) The cam and injection pump pulleys were off by one tooth each (my wrestling the belt on) and the stop solenoid plunger was stuck.

It would not idle but adjusting the fuel screw as Arfur suggested got it to idle.

It revs quite high at idle so I guess the pump is too far advanced.

The timing belt sits slightly adrift of the injection pump pulley which is a bit worrying.

[Dave_Q]

ISTR on my last XUD the belt sat on the outer edge of the pulleys, never fell off though.