Xac's adventures with Cassy (and friends + wife)

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

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Xaccers
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Post by Xaccers » 07 Aug 2010, 20:41

What a day!

Up at 6:30am to get Cassy's engine steam cleaned by a local chap called Garerth, very nice bloke he is too.
Originally he came over during the week while I was working in London and had a go, but wasn't happy with the amount of oily water that was running down the road, so not wanting to upset my neighbours said about going to a truck depot where he has access to a pit this morning.
Now remembering that my fuel pump has been leaking veg (making the BP spill look like a drop in the ocean according to Jim) coating the sump etc in a thick gel like substance which as Jim found out is nigh impossible to remove, the steam cleaning has actually managed to get quite a bit of it off, I can see some of the metal of my sump for instance :D
While steaming the engine as it was running, I noticed the aux belt wasn't turning, then got a spray of water as it kicked in, so that would explain why the battery light had been glowing slightly over the past couple of weeks, with the battery running down slowly.
The rev counter was bouncing around all over the shop even though the engine was idling stably.

Once the steaming was done, and a good chat about running on veg (Gareth has a '51 Fiat belingo type van with I guess a DW8 engine and wanted to know if it could run on veg, so if anyone knows please do tell) I headed off to Weatherspoons for a proper breakfast, then off to get new tyres, Bridgestones this time (Jim they're quiet and grip really well) as after 4 months of driving on the Arrows they're down to cloth on the inside edge! So alignment was done too.

Then off to Chez Jim to start work on Cassy's pump.
With Jim's instructions, I removed the hydraulic pump for access and then the pump sprocket cover which can be removed without removing the engine mount.
Being Cassy, removing everything was pretty easy, although the use of Jim's pump extractor was needed.
Jim spotted that the pump had been worked on before, as it didn't have anti-tamper bolts on the armour.
Cleaning the pump up was not an easy task, the thick veg gel resisted brake cleaner and petrol.
We'd suspected that the issue with the seals was that as they age and harden, the veg is pushed into the cracks, then as it cools and polymerises over night, it expands enlarging the cracks until it gets around the seal.
Jim scraped off a lump of gel by the seal line and it started weeping from there, giving more credence to the theory.
Eventually cleaned up, Jim opened the pump and the old seals were hard and compressed as expected from their age.
Jim's replacement seals are vitron so shouldn't suffer the same fate in 10 years time.
Meanwhile I refitted the pump, adjusting it using the imprints of the nuts and washers as a guide.
Refitted the aux belt and made sure it was tensioned properly.
With everything in place and the timing bolts removed, it was time to test :D
Cassy sounded sweet as a bell, but the K light was flashing rather than being constantly on, and the rev counter was bouncing around again.
Disconnecting the needle lift or TDC sensors made no difference, so time for a Lexia session!
It took 3 attempts to get it to talk to the ECU, which reported the engine was doing 1488rpm even though it plainly wasn't.
Jim went to get an old ECU to test while I removed the old one and spotted straight away what the problem was.
Blue gunk by some of the pins and a bit of water.
Blasting with contact cleaner and Jim's airline cleared it up, and the test gave a working rev counter and constant K light :D

I took her for a spin on the way home, and she is sooooo smooth, but I think the fun screw needs tweaking ;)

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CitroJim
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Post by CitroJim » 07 Aug 2010, 21:33

It was agreat day today Xac :D

The DW8 was most often fitted with a Lucas DPC so sadly, unlikely to be veg. friendly :(

I have to confess that toady I did nothing toward the job except watch proceedings and occasionally lend a hand on the two-handed bits. You did a tremendous job Xac :D Swapping a pump is not an easy job at all. Especially as at one point proceedings were interrupted by a prolonged and torrential downpour!

The reason, not made clear above, for the K light being on is that the replacement pump is a fully mechanical one I refurbished a few weeks ago. It was one I had in stock and found it seized and full of sticky gum when I stripped it. It initially looked to be almost beyond hope but I have to say it makes the engine run like a swiss watch :D

The leaky pump was a nightmare :twisted: It had been leaking over an extended period and was covered in a coat of polymerised veg. It was almost like it had been powder coated and baked. Nothing would touch it and I was reduced to scraping it off :lol:

Inside though, it was a different story entirely. It was squeaky clean and shows no sign of wear; veg. does not damage these pumps at all by the looks of it.

It was fortuitous that the pump had been in bits in the past as it was a doddle to remove the armour and then we were able to transfer the immobiliser block over to the replacement pump and thus obviating the need to do any wiring modifications :D A a bonus, the immobiliser remains fully operational even though the replacement pump was never intended to have one! The only electrical work that will be required will be to remove the K light bulb and rig up a supply from the glowplugs to the cold advance electrovalve.

Because the leaky pump is in very good condition, it's a quick win as it just needs new seals; a full strip is unnecessary.

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Post by Xaccers » 07 Aug 2010, 21:57

The cold advance should be easy to sort, just a wire with a small ring contact on each end running from the cold advance terminal up to the 3rd glow plug terminal away from the cam :)

Really appreciate your help today Jim!

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Post by Xaccers » 27 Aug 2010, 16:28

Greetings from sunny Whitby!

Took us about 5 hours with an hour or so of stops and a bit of a diversion.
Cassy needed her LHM topping up at the start, will have to keep an eye on it as it looks like it is leaking slightly from the bleed screw.
Other than that she's performed beautifully :)
The A169 was closed so we diverted along the coast road listening to classical music.
As we came over the brow of a hill to see Whitby for the first time the music from 2001 was playing, then the hovis advert music on the way down the hill through Normanby, and when the abby in all its gothic splender came into view Bach's Toccata was playing :D

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Post by myglaren » 27 Aug 2010, 17:03

Hah! - I'm going tomorrow, it's my brother's birthday :)

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Post by CitroJim » 27 Aug 2010, 17:56

Excellent :D Is it really sunny?

Delighted Cassy performed well...
Xac wrote: as it looks like it is leaking slightly from the bleed screw.


Ahh, so I wasn't seeing things when last lying under Cassy. I saw the bright green around the bleed screw but wondered if it originated somewhere higher up..

The ball can't be seating well on its seat.

You and Danielle have a lovely holiday :wink:

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Post by Xaccers » 27 Aug 2010, 19:24

Found out it looks like the A169 was closed due to a tanker rolling over!

Will definitely have to swap out the regulator when I get back, that should sort the leak :D

Jim, remember I said that Cassy was giving out white smoke?
She's done it twice, after idling for a long time.
Wondering if it's time for new glow plugs (although she starts fine), or could it be the pump timing is slightly retarded?
Also noticed most of the journey the temperature was only around the 70C mark, was doing a steady 60mph, and it was chilly but could it be time for a new stat?

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Post by RichardW » 27 Aug 2010, 21:27

The words 'head' and 'gasket' popped into my head....but not by any means in the same sentence yet..... hope not! Once it's warmed up, the plugs make no difference, so I'd not worry about that. It could be a bit of oil leaking from the exhaust side seal of the turbo then getting vaporised / blown out when revs are lifted.

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Post by Xaccers » 27 Aug 2010, 22:09

Head gasket was changed when we changed her head a couple of years back so certain it's not that, and the smoke clears after a few miles of driving.
I'm thinking more along the lines of oil leak then, there is one at the back of the engine that I need to investigate further and fix.

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Post by Xaccers » 01 Sep 2010, 20:31

Found and fitted some hub caps for £14.99 as I'd lost one of the originals and the others were a bit scuffed so have been running with none for a while, making the wheels go an ickle bit rusty. Will have to find some matt black paint.
Checked Cassy's oil level and it is spot on the top mark, but also had a hunt for the leak.
Starting at the top, I reached over the cam cover to feel the back of the seal and felt oil.
Now I'd changed the seal a couple of years ago, so it shouldn't have failed that quickly. Got a shock when I felt the cover bolts for tightness and found them wobbling! So tightened them up and will see if that stops the leak.
LHM has dropped a bit while she's been standing out in the road (daren't move her as we'll probably lose our space!), thankfully there's a Boyes in Whitby with Coma LHM for around £5 a bottle, so picked up 3.
Also picked up a bottle jack which will either fit in the boot side panel or in the spare wheel instead of the scissor jack.

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Post by CitroJim » 01 Sep 2010, 21:33

That's a nice result with the rocker cover Xac :D They are only done up to about 8 Lb f anyway so it does not take a lot to loosen 'em..

Have you a spare pressure regulator to sort your LHM leak?
Xac wrote:Coma LHM
Fast asleep on the shelf is it? Hope you can wake it up when you need it...

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Post by Xaccers » 01 Sep 2010, 21:54

I believe I have the LX's old one in my parent's garage, of course they also have a spare Xantia down there which they want me to hurry up and sell :oops:

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Post by Xaccers » 03 Sep 2010, 17:39

Just got back from Whitby via Luton to drop Danielle's parents and dog off.
Did 543 miles with 4 adults, a dog, and our luggage in a roof box and managed a Jim pleasing 42mpg!
It's amazing how much more efficient a car is when a quarter of the fuel isn't running straight out the side of the pump :D

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Post by CitroJim » 03 Sep 2010, 18:39

Excellent :D

I am delighted 8-)

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Post by Xaccers » 19 Sep 2010, 12:38

Took Cassy over to Jim's yesterday to check out a few leaks and a possible one at the rear.
Brady was there having a LHM and sphere change on his exclusive.

I had a look under the back where the HC's rubber cap was bulging and the first thing I noticed was that with the suspension on low there was no bulge.
With a container underneath incase any LHM escaped I pulled off the cap and was relieved to find it was bone dry.

So I moved to the font where there was an oil leak, a LHM leak from the regulator end and 12mm screw, and a LHM leak over the pump side.

Looking from underneath I wiped up all the free oil and saw the leak coming from the top vacuum pump side of the engine.
From above I checked the back of the cam cover as this had been loose in Whitby, and it was still dry, so next was the vacuum pump and I could see a bead of oil running out the bottom of it.
About two or three years ago, when we replaced the cam/head the original o-ring had failed and Jim provided one from a standard set to make do with a view to replacing it with the proper one.
Well that was the plan which I had comepletely forgotten about :oops:
Taking the pump off the o-ring was totally flat, and looked like it had melted slightly. It was a real pain to get out and very hard.
Thankfully Jim had a spare pump with a decent looking o-ring so we fitted that and the leak is gone.
I'm going to order a blanking plate (as I don't need the pump) and new o-ring for the old pump so Jim can have them both.

I moved onto the regulator, and it didn't appear to be leaking from the bleed screw anymore, so maybe some dirt had worked it's way in causing the leak and then with more use of the screw cleared itself along.
The end bolt wasn't tight so I nipped that up and it looks like it's not leaking from there anymore, but time will tell.

Over on the pump side, there was plenty of LHM hanging on to the bottom of the A/C compressor, but from the top I could not see where it was coming from, the pipes were dry.
Jim spotted that the blanking plate was leaking onto the alternator, and managed to find the o-ring for it.
5 minutes later and that was done.

Now all I have left to do leaks wise is clean up the massive oilslick on my drive and down the road.
You see, I tackled it one evening last week, using the swarfega oil remover stuff.
It did a great job, but I wasn't able to use enough water to flush it all away, so rather than removing the oil, it's spread it out (very thinly) and left a long dark grey smear down the road to the next drain.
:oops: