2.2HDi C5 Exhaust manofold gasket

h2ocooler · Post by **h2ocooler** » 07 May 2009, 00:14

Hi All
Had to do 2 airport runs, one yesterday and then one today (family not a taxi) then went to work after, on the way home i could hear what sounded like a very loose valve clearance, roughly half engine speed, not heavy but there when you drive past parked cars, 40 miles later when i got home, I had a look under the bonnet and exhaust smoke coming from the back of the engine along with the now unmistakable sound of a manifold blow.
Is it an easy job to get too on the 2.2HDi or a real pig, the Omega i had had a manifold blow but the engine had to come out to do it

Regards
Rob

wheeler · Post by **wheeler** » 07 May 2009, 08:57

I dont imagine it would be a very nice job at all, is it definitely the manifold gasket & not leaking injector seals ?

h2ocooler · Post by **h2ocooler** » 07 May 2009, 15:13

Hi
Not 100% sure on the manifold but no loss of power it seems will have to look closer, are the seals common on the HDi then?
Rob

wheeler · Post by **wheeler** » 07 May 2009, 19:04

h2ocooler wrote:are the seals common on the HDi then?

Certainly a lot more common than the exhaust manifold put it that way. If you take off the plastic engine covers there will be a black build up around the injector if its leaking, its the seal into the cylinder head that leaks out combustion gasses.

cachaciero · Post by **cachaciero** » 15 May 2009, 19:03

Which was it ?

Just out of interest you understand

Cachaciero

MikeT · Post by **MikeT** » 15 May 2009, 20:22

wheeler wrote:
h2ocooler wrote:are the seals common on the HDi then?
Certainly a lot more common.....

Interesting to note that Ford have "revised" their seals to make them a bit beefier owing to the huge cost of warranty repairs claimed for injector failures

h2ocooler · Post by **h2ocooler** » 19 May 2009, 00:25

Hi All
Finally had the time to have a look at the weekend and found that Number 1 injector was indeed leaking.
I got the new rings today and removed the injector, cleaned all the soot off of it only to find there was no copper seal fitted in the first place, worse still, there is a grove burnt in the head where the ring is supposed to seat. It ia about 1mm wide and about 1 -1.5 mm deep the full width of the seat. Looking at the injector i think they have been replaced as the tip was very clean with no carbon build up at all.
I think it has been leaking for a long time judging by the amount of soot around and that the plastic sleeve/locating spacer at the top of the injector has burnt away, it looks like that was sealing the injector for a while till it gave up the ghost.
Now the question is is it possible to have the head seat recut and a thicker (or 2) washer(s) fitted to ensure the injector is in the right place or is it a new head????
I tried fitting a new washer but it leaked straight away but did the following.
I heated up two of the washers to soften them but got them too hot managing to melt them together in one spot, then had a brain wave and cut part of the second washer off leaving a 1mm wide by 1.75mm deep "lug" on the washer, then put it in the hole ensuring the "lug" was over the groove, refitted the injector to squash the "lug" into the groove and hey presto it doesnt leak so its ok for now, dont know how long it will last though.

All ideas etc MOST welcome.

Rob

Post by **myglaren** » 19 May 2009, 06:55

When mine were first checked it was found that one of the washers had burned away completely, which is likely what happened to yours.
They have all been replaced twice in two years.

wheeler · Post by **wheeler** » 19 May 2009, 08:58

There is a thicker repair washer available from citroen. part no 198145.

h2ocooler · Post by **h2ocooler** » 19 May 2009, 19:22

wheeler wrote:There is a thicker repair washer available from citroen. part no 198145.

They are the ones i got, found in another post that there is a grinding tool available for £85, going to look at getting one if it leaks again.
Rob

Xantidote · Post by **Xantidote** » 19 May 2009, 21:55

Does this grinding tool allow one to do the job in-situ? If so, what happens to the swarf?

Martin

Post by **myglaren** » 19 May 2009, 21:59

Xantidote wrote:Does this grinding tool allow one to do the job in-situ? If so, what happens to the swarf?

Martin

Certainly a major concern. Not easy to keep it out of the cylinder.

h2ocooler · Post by **h2ocooler** » 19 May 2009, 23:23

Looking at the tool it has an extension that goes into the hole for the injector port, doesnt say on the website about having to remove the head but yes the swarf would be a bit of a worry, was going to grind it with a hoover in the hole to get as much of the swarf as poss, plug if i greased the tool it should stick to the grease as well.
I am going to contact the company and ask them for advise.
Rob

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2.2HDi C5 Exhaust manofold gasket

2.2HDi C5 Exhaust manofold gasket

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