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MikeT
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Joined: 11 Jun 2007, 16:17
Location: Christchurch, Dorset. UK
My Cars: 2005 C5restyle 1.6HDI 16v 110hp VTR Estate
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Post by MikeT » 10 Oct 2008, 09:33

Sorry joss, that's a negative. I had no reason to make spares and without the proper tools, it wasn't a quick and easy job. I could probably muster the raw materials for you but that's about it. If you've got a drill, hammer, file and cutting tool (hacksaw or snips) you could make your own in an evening.
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98 S2 Xantia Hatch 1.9TD 143K
CX 2400 GTi

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MikeT
Posts: 3813
Joined: 11 Jun 2007, 16:17
Location: Christchurch, Dorset. UK
My Cars: 2005 C5restyle 1.6HDI 16v 110hp VTR Estate
x 43

Post by MikeT » 17 Oct 2008, 22:03

One step forward two steps back today :roll:

My voluntary helper cancelled this afternoon.
I then spent way too long and used too many scotchbrite's trying to get all remnants of old gasket off the block face.
Not to mention time wasted having to carvac out all the fluff and dust that created.
I then fitted the turbo and EGR to the exhaust manifold and mounted that on the exhaust behind the block only to find a disobedient clic clip that wouldn't clic or clip onto the EGR pipe :roll: And how was I supposed to fit the inlet manifold side anyway?
Time for a rethink.
Changing tack I decided to test the battery only to find it was flat. That was despite it being trickle charged by a solar panel that "works even on cloudy days". The battery did had enough charge to work the central locking, interior lights etc but it was reading less than 12v so had to come off.
I didn't relish the idea of overstretching to reach all those rear of engine parts and eventually convinced myself to try a different approach which I'll hopefully begin tomorrow.
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CitroJim
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Post by CitroJim » 17 Oct 2008, 22:25

I know what you mean Mike. Some days go really well and others seem a bit doomed really. Good job there's always a tomorrow.

The EGR pipe to the inlet manifold is not too bad Mike. Attach it to the EGR valve first and thread it into the inlet manifold as you go. It might need a bit or origami applied to it and if I recall, it's a bit springly and not happy to stay where you want it. Those clips are little devils though. I have a large pair of side-cutters that do the job well. I have seen screw-up clips but never seen where they might be bought from.

Your solar panel might work under normal cloudy skies but by golly, ours this year have been anything but normal. It would have to have magical properties and defy the laws of physics to give any useful output in our climate. I'm sure solar power is wonderful but it needs one thing we lack - the sun :lol:
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MikeT
Posts: 3813
Joined: 11 Jun 2007, 16:17
Location: Christchurch, Dorset. UK
My Cars: 2005 C5restyle 1.6HDI 16v 110hp VTR Estate
x 43

Post by MikeT » 18 Oct 2008, 22:38

My assistant was keen to make amends today and turned up at lunchtime :lol: He spent the first hour supervising me (questioning how EGR's work etc) while I sorted out the bags of studs to make a mock fitting.... then we went for lunch :lol:

Contrary to Haynes, refitting will not be a reversal of the removal procedure. :twisted:

So here's the head lying on it's front face exposing the rear we rarely see, with the studs and gasket in place. As you can see, there's little point in getting these heads ported :D and even less reasons to polish them.
Image
I did find the all-in-one gasket not such a perfect fit and thought I'd have to cut it round the water pipe but I first tried reversing the gasket. 8)



With the studs in place I had to fit the inlet manifold first then the exhaust manifold though either way is possible if needed. There are six spacers and a short bracket needs to placed over the exhaust studs before the nuts go on. Note, the inlet nuts are steel while the exhaust nuts are copper. Maybe I was impatient but I couldn't find the torque values for these in the Haynes book so I tightened them as much as I dare.
Image

Although the turbo is fitted here I may be forced to remove it and pre-fit it to the exhaust flange in the car first. The total weight isn't quite as bad as I thought though it will still have be a two-man lift & carry job, particularly when it comes to lowering it onto the block.

I can afford to wait for new clic clips before I put the head back on. That will happen next week, assistant willing :lol:
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98 S2 Xantia Hatch 1.9TD 143K
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myglaren
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Post by myglaren » 18 Oct 2008, 22:43

OOoooooooooh, Shiny!
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Post by jgra1 » 20 Oct 2008, 16:20

A polished job that, Mike :) very nice
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MikeT
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x 43

Post by MikeT » 25 Oct 2008, 19:28

Many lessons learnt on this job, I can tell you :lol: Pity it's not something I hope to be doing again as it'll be a lot, lot easier and quicker next time.

As you may have realised, the manifolds and turbo were pre-fitted in the above picture. My reasoning was I could save myself some backache by not having to do so much work behind the engine - well it seemed like a good idea at the time... :lol:

So, with the aid of an assistant, we carried the head out my flat, around the block to the car park and raised it into the engine bay (ooO me back!!!) and proceeded to lower it onto the two headless bolts I'd made earlier (the single dowel provided by Citroen is next to useless because the gasket can pivot on it and move offline) but the manifold was catching on the firewall. :roll: So we put the head in the boot of my granada and removed the turbo, re-fitted the turbo to the exhaust and tried again. Nope, it wasn't having it because of the headless bolts tilting backwards, leaving less room than without them. I tried reducing their length and that worked :D The head lowered smoothly onto the block and, pleased with ourselves, began inserting the new head bolts....

However, my heart sank when it came to the rear bolts because the inlet manifold and EGR pipe were blocking access. :evil:

Off it came again and I decided to pack up my tools and bring the head indoors for another day - back to the drawing board as they say.

:idea: Off came the inlet manifold, studs and EGR pipe. I fabricated a tighter fitting EGR blanking plate which wouldn't need the pipe to complete the seal, just the clic clip and a smothering of gasket sealant. The inlet manifold and studs will have to be fitted in-situ but at least the exhaust manifold can remain. Additionally, I decided I'll try and remove the turbo from the exhaust and fit it back onto the exhaust manifold on the head :idea:

So, this morning, my assistant carried the head assembly and rested it in the boot of my Granada while I removed the turbo from the car and with it pre-assemebled on the head, we tried again but this time the headless bolts were restricting movement too much, so off came the head again while the headless bolts were junked.

Eventually, with a bit of careful shuffling, we lowered the head onto the gasket and block - at last! Though it was fiddly geting the gasket to stay in line as predicted. New headbolts were inserted and torqued the first two stages - I don't have an angle disc yet and prefer not to approximate.

My assistant had a date to keep so we packed up for the day as we both had cold hands and rain was threatening anyway.
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98 S2 Xantia Hatch 1.9TD 143K
CX 2400 GTi

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MikeT
Posts: 3813
Joined: 11 Jun 2007, 16:17
Location: Christchurch, Dorset. UK
My Cars: 2005 C5restyle 1.6HDI 16v 110hp VTR Estate
x 43

Post by MikeT » 29 Oct 2008, 13:23

Due to family matters I'm staying at my sister's home while she and my eldest nephew are on a special holiday until Sunday. In short, I've given my flat over to my BIL who has just been discharged from hospital - they discovered he's suffering from a brain tumour. Unfortunately, it's a particularly aggressive (grade4) malignant tumour with an average life expectancy of 14 months if treated (radiology and chemotherapy).

As a result, my life is on hold so I can supervise my younger nephew, keep the house in good order and run errands for my BIL if and when needed. Therefore I won't be accessing the internet as frequently as before so forgive me if I've missed any posts & PM's. Additionally, I'm not able to do any work on the Xantia either

Normal service should be resumed next week though.
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jgra1
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Post by jgra1 » 29 Oct 2008, 13:36

god...

brings things home Mike, very sorry for all concerned :?
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MikeT
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My Cars: 2005 C5restyle 1.6HDI 16v 110hp VTR Estate
x 43

Post by MikeT » 10 Nov 2008, 12:16

Well one week away turned out to be three but I'm back now. Long and the short of it was my BIL got discharged from hospital with no fixed abode (social services cock-up) owing to the fact he ruined his home leaving the bath running. As I was minding my sister's home I gave my flat over to my BIL. Thankfully, his boss has now allowed him temporary accomodation until he begins radio/chemo therapy which is in a few weeks. Poor bloke, I don't think he fully understands what's coming. :(

Anyway, I've got a lot of chores and duties to catch up on then I'll be back under the bonnet finishing off the job I started way back in May. Cold out isn't it? :roll:
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98 S2 Xantia Hatch 1.9TD 143K
CX 2400 GTi

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MikeT
Posts: 3813
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Location: Christchurch, Dorset. UK
My Cars: 2005 C5restyle 1.6HDI 16v 110hp VTR Estate
x 43

Post by MikeT » 20 Nov 2008, 18:38

Finally got a chance to wield my spanners again today but didn't accomplish much as I've pretty much forgotten the order of rebuild! :oops:

First job was Stage 3 of torquing the head bolts. I made a simple cardboard angle gauge and round about 180 degrees into the first bolt my T55 bit sheared :shock: Initial thought was the head bolt had gone because it takes quite some force at that point - scary!

Third shop luck, found a good quality Torx bit and finally got the head fully torqued. As stated, it's quite scary the amount force required to go 220 degrees more after 60nM ... even using a long torque wrench I was at the limit of my strength.

After that I felt as if I'd lost interest, I just didn't have any enthusiasm or perhaps it's the usual pre-christmas depression I tend to get this time of year (bah humbug) :P either way I only managed to refit the glowplugs & lead before locking it up and toodling off to see my BIL.

Now I've had time to reflect, I haven't lost interest but I don't have full confidence in my repair - I didn't test the head for instance and the internals have ample time to rust and corrode. Additionally, I'm facing insurance renewal in ten days and that being a 12-month commitment means I need to know if the Xantia is up to it.

Anyhow, tomorrow's another day and my nephew has promised to give a hand in the afternoon, although I've got to be on standby to collect my Dad from hospital so might not be getting much done until the weekend. Did they predict freezing temps soon? :(
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myglaren
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Post by myglaren » 20 Nov 2008, 20:22

Now I've had time to reflect, I haven't lost interest but I don't have full confidence in my repair - I didn't test the head for instance and the internals have ample time to rust and corrode. Additionally, I'm facing insurance renewal in ten days and that being a 12-month commitment means I need to know if the Xantia is up to it.


Try insuring it on a monthly plan so you can walk away from it if the car doesn't make it.
Some charge astronomical rates but others are more reasonable.
IIRC Tesco were pretty good (never used them though, been with Liverpool Victoria for years)
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MikeT
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x 43

Post by MikeT » 23 Nov 2008, 18:35

Good point Steve, I forget about the short-term, ableit expensive insurance options, thanks.

Damn it's cold! Worse when handling metal parts, tools and ground. I'm now ready to admit I'm not fit enough for this DIY, at least not in this weather but I started, so I'll so finish.

So with the head torqued it was time to fit the inlet manifold and that single bolt that it slots into proved to be my undoing yet again. I had to back it out so far that I couldn't get to it to tighten once the manifold was in place and all the studs fitted, tightened then bolted up. (I've seen poor engine designs from a maintenance point of view but this is the worst type and I'd be interested to know if Citroen train their mechanics to remove the engine for a head gasket job as it must be so much easier.) As a result I will have to remove the IM studs and try to refit it with that stupid bolt screwed in a bit further. For the sake of 2-3mm, that one bolt is a true pain.

Turbo oil feed & return pipes refitted with new gasket and cleaned filter and hose couplings attached turbo side and for good measure I've fitted extra long actuator hoses ready to accept a manual boost controller. I do also want to fit an exhaust bypass but that'll have to wait for another day so bolted it up to the downpipe with new heat washers. Hopefully the exhaust gasket is still good but if not, will be a doddle to repair when the exhaust mod gets done.

So onto the cambelt idler pulley, tensioner and engine mounting bracket. Totally forgot order of fitting and placing of bolts but thanks to jgra's pictures soon worked it out. Got stuck when it came to fitting the tensioner lever owing to the spring and plunger acting against it. And, as my nephew said, that cam pulley is sharp! :lol:

Cold stopped play and I was suffering badly with neck and hip pains prompted me to pack up my tools. Finally seeing the light at the end of the tunnel though the mods I planned will have to wait a little longer.
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98 S2 Xantia Hatch 1.9TD 143K
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CitroJim
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Joined: 30 Apr 2005, 23:33
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x 689

Post by CitroJim » 23 Nov 2008, 19:34

Delighted to see some good progress on this Mike, despite the rather cool weather. I know so well what it is like to work on a car outside at this time of the year although, on balance, I perfer the cold and dry to the cold and wet :D

Hope the aches and pains are all gone now Mike and that progress xcan continue if the weather breaks out kind again :D
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MikeT
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x 43

Post by MikeT » 23 Nov 2008, 23:41

Hi Jim and welcome back :lol:

As you know, I've been very carefree about when I worked on the car but I've now got a target of getting it running reliably by the 30th - then the fun begins.
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