Citrojim's Ka, Saxo and Bike Tales

Tell us your ongoing tales and experiences with your French car here. Post pictures of your car here as well.

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Citroenmad
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Post by Citroenmad » 05 Jun 2011, 21:23

Its an interesting thread to me that one, very good to read what has been done, what is likely to be need doing and general info on the car from before I got it, something rarely given when buying a car. Though im happy with the suspension side of things, the ride and handling now seems spot on.

With that in mind do you think you might attempt Juliets with the engine still in the car? Its probably what I would go for unless the car needs other things.
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Post by CitroJim » 05 Jun 2011, 21:36

Yes indeed Chris. If I can avoid removing her engine I will. Funnily, if she was a V6 I'd not even contemplate not removing the engine as it's actually easier than an Activa. The engine and ML5 gearbox is incredibly wide and as the gearbox tucks under the chassis rail the engine has to come out with a good old lateral tilt. The V6 and it's huge autobox is actually much narrower overall! Also, unlike the V6 you can't easily unbolt the aircon compressor and leave it in the engine bay whilst lifting the engine. Really, I don't want to have to degas the aircon and I'm sure Xac would be happy too as it's only been recently regassed after fitting a new receiver/drier.
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Post by CitroJim » 06 Jun 2011, 18:39

Good work on Juliet today :D I popped over to see Pleiades and handed over her pump and regulator for checking along with my spare V6 pump for eventual fitting to old V6.

Juliet responded well to some intensive spannering around her turbo. I now have the top oil and water feed pipes disconnected, the big alloy turbo pipe off, which the aforementioned oil and water pipes are clipped to. The oil feed connection to the turbo is a bit of a tricky one but luckily the other end of it is on a flexi pipe so once released from the turbo it can be placed well out of the way. The water feed pipe was disconnected at both ends and this is now floppy too.

The turbo heatshield bolts came out without a struggle and most of the manifold nuts appear to be loose!!!

The job started badly but things are looking much better now :D :D :D

There's a lot of tricks to doing the job and I'll still not call it an easy one by any means...

I hope that tomorrow will see the new manifold gasket ready to be fitted...
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Post by Xaccers » 06 Jun 2011, 20:17

Fantastic news Jim!
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Post by CitroJim » 06 Jun 2011, 21:57

Xac wrote:Fantastic news Jim!


Even better, at close of play, the score is 10 manifold studs off (some of those are a bit hard to reach), turbo bracket undone (mega tight, needed a reverse flute socket on top of the torx head to get enough torque to it) and manifold sitting half an inch away from the head :D :D :D

Sadly, the exhaust flange nuts and bolts, the springy ones on the brillo pad sandwich, are toast and will need to be sawed off and replaced. There's nothing left of their heads through rust. I just can't get any sort of grip on them.

We're winning but what a parlarva!
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Post by CitroJim » 07 Jun 2011, 13:08

Done it :D :D :D :D

Here's the manifold sitting about an inch and a bit from the head:

Image

And here's the remains of the old gasket :shock:

Image

Not much of it left at all, the fire rings had just crumbled to dust...

Bit worried about the whiteness of ports 2 and 3...

Not only that but I used a method that dispenses with the additional work of splitting the turbo off the manifold and disconnecting the cat from the turbo outlet :D :D :D

The job with have been much easier on an LHD car as the steering pinion would not have got in the way :twisted: With gentle jacking and pulling the engine forward off it's RH mount just enough clearance can be gained...

So, what looks to be an absolute, total and utter nightmare just turns out to be a complete nightmare of a job.

Just got to put it all back together now :roll:
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Post by Xaccers » 07 Jun 2011, 15:19

You're amazing Jim!
I'm going to have to bring over the new door and rear bumper before you run out of things to do! :D
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Post by CitroJim » 07 Jun 2011, 17:22

The new gasket is fitted and the manifold is back on :D

Xac wrote:I'm going to have to bring over the new door and rear bumper before you run out of things to do! :D


Hey :twisted: Hold on, there's a lot of mechanical work do yet before we get into cosmetics!!!!!
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Post by Xaccers » 07 Jun 2011, 17:28

CitroJim wrote:The new gasket is fitted and the manifold is back on :D

Xac wrote:I'm going to have to bring over the new door and rear bumper before you run out of things to do! :D


Hey :twisted: Hold on, there's a lot of mechanical work do yet before we get into cosmetics!!!!!


Look, I only did it the once, and that was for the Rocky Horror Show! ;)
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Post by CitroJim » 07 Jun 2011, 19:06

Xac wrote:Look, I only did it the once, and that was for the Rocky Horror Show! ;)


I only did it once as well and that was in Khartoum :)

I find Juliet has a split inboard CV boot on the nearside :(
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Post by Xaccers » 07 Jun 2011, 20:53

Danielle now wants to get you tipsy to find out about "Khartoum" :D
She says duck breast will also be on offer.
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Post by CitroJim » 07 Jun 2011, 22:31

Xac wrote:Danielle now wants to get you tipsy to find out about "Khartoum" :D


Oh yes, duck will be great :D Plenty enough temptation to tell of my Khartoum adventures :wink:

The manifold gasket job is done! It went all back together a bit easier than it came apart.

Here's the evidence. All that's left to do, on that job at least, is to fit the other half of the hot pipe and fit the cold pipe...

Image

It was a heck of a job and getting some of the manifold nuts back on and tightened was a game. It was a job needing the dexterity of a brain surgeon and the flexibility of the India Rubber Man :roll: Fir several jobs it was necessary to kneel on the slam panel to gain access to the manifold nuts...

The most difficult bolt of all was the one under the ignition coil that secures the turbo coolant pipe to the block.

I've been taking lots of photos for a planned write-up of the job although a lot of the work was impossible to photograph due to space limitations.

Space and access really is at a premium for this job but once again Mr. Citroen showed incredible design flair to make the job just possible. Some thought clearly went into the turbo installation on the TCT engine.

Funny how after spending a day down there it seems to get more spacious and access seems to improve as time goes on. It's just an illusion though...

The job was made easier by two main things, good old Plus Gas and ratchet spanners :D What would we do without them?

Anyone know why the TCT has such an odd manifold gasket? Is it a heat shield as well as a gasket? Looking at the old one, it had been jolly hot at some point. It was warped and there was a big crack in it radiating out from No. 2 port.

I can see no logical reason why No.s 2 and 3 ports were so white looking unless it was all to do with the leak. Apart from that, unless those two cylinders are running weak due to bad injectors I don't know. All I do know is that apart from being very noisy it seemed to be running fine...

Next jobs will be the refitting of the front ram and making up a new rear ram bush followed by the replacement of the split CV boot.

Hopefully, when that's done, the pump and regulator will be ready for refitting...
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Post by Xaccers » 07 Jun 2011, 22:44

I'm trying to remember what the plugs were like when I replaced them as that'd give an indication on any lean running wouldn't it?
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Post by red_dwarfers » 07 Jun 2011, 22:50

Certainly cracking on Jim :D

Kneeling on the slam panel, what a picture that must have been :lol: Still, it saves the backs of the knees getting sore from leaning up against the front of the car!

I bet it would be really interesting to sit in on some of these meetings where they decide how everything is going to be laid out. There's loads of factors that they need to take into account and what with engine and car design costing so much they've only really got one chance. A facinating thought.

Another thing that would be interesting is if it where possible for inanimate objects to talk on some occasions.
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Post by Citroenmad » 07 Jun 2011, 23:01

Good work Jim, its not taking you long to get that Activa up to scratch again :)

red_dwarfers wrote:Certainly cracking on Jim :D
Another thing that would be interesting is if it where possible for inanimate objects to talk on some occasions.


That would certainly be a big help :lol:

I suppose in a way its already happened, through Lexias and the likes :P
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Chris
16 C4 Cactus BlueHDi Flair
05 C4 2.0 16v Exclusive
54 Audi A2 FSi SE
51 VW Passat V6 TDi Estate

Family Citroens:
64 C4 Cactus BlueHDi Feel Red
15 C3 Picasso 1.6HDi Exclusive
56 C5 2.0HDi 138 16v VTR Estate
95 C15 6-wheel
55 Traction 6H