Activa exhaust manifold gasket

[andmcit]

Right, been here a few weeks ago with a TCT Xm and now need to tackle the
same task on a V reg with AC. Is there any nasty gotcha that is particularly
evil? I found it wearisome on the Xm but just a mechanical undo remove
and refit job dropping the whole turbo away enough to get in and swap the
metallic 40 quid gasket.

Space actually looks the same if not better at the back of the engine on the
Activa!! Certainly as far as access from the top.

Stories of driveshaft removal and dropping the engine or canting it forward
on an Activa don't fill me with confidence or enthusiasm.

Andrew

[CitroJim]

Gareth (Xantiaman) is yer man Andrew, he's done it and documented it in his blog...

It'll be the same roughly as on the XM. It is possible but it's a bit of a ball-ache...

[andmcit]

I must've missed the write up - I recall seeing Gareth mention he was tackling
the job and planned to write a guide up but I never saw it.

The real git of the job on the Xm was accessing the torx mounting bolt heads
that attach the turbo to a support bracket on the block - damned stupid design
as everything is in it's own way.

Andrew

[andmcit]

What a complete nightmare - ball-ache doesn't begin to cover it. I struggled
through and upon almost "finishing" the rebuild cold, p!ssed off, tired and
in the dark [not a good scenario] realised with a horrible sinking feeling the
new thing I fished out from the subframe on retrieving some dropped tools
was one of the compressible gaskets that are skimpily glued or 'attached' to
the metal backing plate of the whole gasket. Must've knocked off on one of
the studs getting it all aligned up and missed it in the rubbish access/visibility.

The job effectively needed a complete re-run although I blazed through it
in a bit of a rage with myself in proper warm bright daylight after a decent
rest. This rate, I'll be quite adept at it after fixing then Xm and the Activa.

Real evil "highlights" are accessing the jubilee's holding the turbo feed pipes,
the bolts on the turbo's bracket and nuts holding the manifold. Then there's
naff all space the get the spring loaded cat mounting bolts and the feed pipe
connection onto the turbo bearing.

My arms look like I've taken up self harming with some people asking me if
I'm OK and coping with things...

maybe that's what owning an Activa is!?

I'll run through a blow by blow guide if it helps the next unfortunate candidate.

Andrew



<<edit typos corrected>>

[CitroJim]

Well done Andrew

Top job my good man!!! A blow by blow will be most valuable as Xac and I have to do the same job on his soon...

Finding a fire ring after the job has been done is enough to make you cry

I know what you mean about skin damage and self-harm! You should have seen my hands and arms after my epic Activa radiator trials

I say it again, well done

[andmcit]

Cheers Jim. I wasn't so much close to tears but apoplectic and about to mete
out some harm to the car in a Basil Fawlty 'losing the plot' tree branch scenario.

I've been here before with a CX GTi turbo clutch swap. Realised after a lot of
faffing and panicing why the car wouldn't start back up after FULL reassembly
= yep, the slug sensor which is removable from the flywheel had been
knocked off and was sitting at the bottom of the bellhousing so there was
no signal being sent to the sensors so the whole job needed doing all over
again for the practice.

I did consider taking pictures for the record but it's just as well I didn't the
first time around as I couldn't bear to see a permanent reminder mocking me
forever. Likely as not the camera may have been sent into orbit too in the rage
of the moment although generally, spannering [in the right conditions] can be
quite calming and rewarding. Like I say, in the right conditions!!

Condolences for Xac's manifold mind...

Some of the tight spots are unbelievable - I currently feel like my right hand
has a broken wrist it hurts so but just bruising and scratches. cannot imagine
a larger turbo of how it would even lift out!!

Another particular low point was realising that leaning the engine forwards
supported by a trolley jack undoing the driver's x2 engine mounts was the
worst possible thing I could've done to improve access to the manifold's
face/studs and enough room to drop the turbo back.

Space is at a premium and won't really work if there are x2 of you!

The only point x2 people may help is supporting and manipulating the turbo
from below the car whilst someone from above finds the sweet spot to align
the manifold gasket in. I ended up using blue Hylmo cement on the reused
gasket's faces which was particularly mucky too.

Andrew

[XantiaMan]

You put Hylomar on the exhaust manifold?? Brave man, that will soon burn off. I used nothing on mine, just got the face on head and manifold spotless, also replaced the fire ring, i'd slit my wrist if it had gone to the hassle and it started blowing again.