Brief Encounter II - The Sequel

red_dwarfers · Post by **red_dwarfers** » 28 May 2009, 20:15

Ideal Jim!
*fingers and various other body parts crossed* I really am hoping it does work for you after all that PERCY WAT SIT.

Im looking forward to be given a spin in it (no doubt with a car full of other FCF V6 fans)

jgra1 · Post by **jgra1** » 28 May 2009, 22:46

great Jim

I feel I should be helping put her back in .. a bit snowed under with the projects

going to be a nice weekend for your job though.. will see how things go

John

Post by **CitroJim** » 29 May 2009, 13:23

Kev,

I'm running very short on stocks of PERCY WHAT SIT after this job, I can tell you. I must see if GSF have any in available...

I have rather a lot of anatomy crossed too. It's nailbitingly tense right now as there was/is no way to test anything until it is fully back together.

I'll be trembling like a jelly when I first go to turn the key

jgra1 wrote: I feel I should be helping put her back in ..

No worries at all John

I appreciate it greatly you helped me with the difficult job of removing the engine! DickieG is coming up on Sunday for the refit.

I realise I stripped too much off the engine to remove it although in my defence, I removed a lot of the ancillaries in the forlorn hope that I could take the gearbox off and leave the engine in place. In the event, it was a blessing the engine had to come out or I'd never have discovered the colling system full of something horrible or that the alternator was full of LHM! Also, everything has had a good inspection, a clean and where necessary, an overhaul.

It took longer to put the final minor ancillaries back on the engine than doing the big jobs. I replaced the thermostat and also it's seal that looks like a two-lipped oil seal that lives deep in the housing. The old seal needed to be gently cold-chiseled out (very small cold chisel) and the new seal pressed in. As the seal is in the bottom of the housing, there's not a lot of space to work. I also replaced the O rings on the thermostat housing and the small O ring on the water supply pipe from the expansion bottle.

I can't help feeling theat changing the thermostat in-situ is not a pleasant job. It wasn't exactly easy with the engine out.

All the coolant pipes are back on but I've not yet connected the transmission cooler as I want to thoroughly flush the block and pipes outdoors just before the engine drops back in and in doing this I don't want to risk any crud that may still flush out get anywhere near the transmission cooler.

The Pressure Regulator is all on and piped up ready to go. I also have a brand-new accumulator sphere to fit as a last job as the accumulator is not exactly fantastically accessible.

I also replaced the throttle body and used a new gasket on it. I bought a new gasket but had to buy 10 to get one so anyone who wants a V6 throttle body gasket, I can supply as I still have 9 of them!!!

At the end of the job last night I marvelled at just how complete the engine and gearbox is when it is ready for fitting. It'll almost be like dropping in a cassette

When Citroen describle the assembly as a power unit they're not far off...

I must remember that the flex plate bolts are not yet fitted as I can't get to the flex-plate until the engine is up in the air on the hoist.

I must also remember the engine is currently dry of oil. What a shame it would be if in my enthusiasm I fired up the engine with no oil. That would really ruin my day.

This evening I shall look at the best way of refitting the exhaust headers to the manifolds. The joints are made by the most evil spring clips you've ever seen

They're like over-grown EGR valve clips but with springs inspired by Arkwright's till

The fabrication of a special tool may be on the cards...

Here's another view of the complete power unit..

Sid_the_Squid · Post by **Sid_the_Squid** » 29 May 2009, 15:28

Fantastic stuff Jim, I’ve really enjoyed reading this blog, good luck with the re-fitting and subsequent testing.

so anyone who wants a V6 throttle body gasket, I can supply as I still have 9 of them!!!

I will be interested in one of these in the near future as, I had an air leak arround the throttle body as the gasket is very old, and would not seal, used some silicon instant gasket (very sparingly) as a temp fix. Solved the issue for the short term, I’m planning on chaining the spark plugs later this year, so makes sense to do a proper job, don’t suppose you have any gaskets for the intake manifold, as it looks like that would have to come off to access the rear 3 plugs.

I look forward to the next blog installment, hopefully of you waxing lyrical about driving your Xantia V6

Post by **CitroJim** » 29 May 2009, 19:57

Pleased you're enjoying the blog Sid

Send me a PM with your address and I'll pop one of those throttle body gaskets in the post for you

The inlet manifold does need to come off to get at the plugs in the rear bank and it's easy enough. There's no need to remove the throttle body to do this but you do need to disconnect the MAP sensor connector and the fuel regulator sense pipe from the RH end of the manifold. Also, you will find it helps to loosen the lower studs in the two rear lifting eye brackets to assist the removal of the two studs that bolt the rear of the manifold to the lifting eye brackets.

You may find the inlet manifold gasket a bit sad and it's a good idea to replace it. Dealer only sadly, under part no. 0348 K7. I reckon, whith care, a gasket should last a couple of plug changes. To lift the rear bank plug lead assenbly, you'll also need to loosen the bracket that supports the wiring loom that run across the RH end of the rear bank.

Blow any debris out of the plug wells with an air-line and if the plugs are tight, loosen then half a turn and spray Plus-Gas down around them and leave for a few hours. Blow any excess Plus-Gas away with an air line and then wipe the wells with a soft rag to remove any remaining muck. You'll be amazed at how deeply recessed the plugs are and a proper deep plug socket with a rubber gripper in the top of it is absolutely essential. Plugs are the same as used in any other petrol Xantia and available very reasonably from GSF.

I looked at the exhaust header clip problem this evening. This is the offending clip...

I tried a normal pair of circlip pliers on it but they just succeeded in twisting the clip rather than opening it up as the taper points did not make flat contact with the faces of the clip. I then thought about it and came up with the idea of making a couple of pads out of aluminium blocks that would slip over the ends of the prongs of the circlip pliers. I came up with this:

This is the tool in action:

Works like a dream

Deanxm · Post by **Deanxm** » 29 May 2009, 20:53

Good to see its coming together nicely Jim, and good luck for the weekend!!, not that you will need it though im sure

Also, that exhaust header........you could just put a standard split exhaust clamp on it, but im not sure which of the two would be easyier to do up with the engine in though........................

D

jgra1 · Post by **jgra1** » 30 May 2009, 00:23

nice simple tool Jim,

my threaded bar took a while to seperate the pesky thing!

addo · Post by **addo** » 30 May 2009, 01:33

I'd be all for whizzing the garden hose through that tranny cooler, just to make sure it has fairly unobstructed flow.

Good work on it all, though.

Post by **CitroJim** » 31 May 2009, 21:01

addo wrote:I'd be all for whizzing the garden hose through that tranny cooler, just to make sure it has fairly unobstructed flow.

I replaced the cooler Adam and flushed the new one

Firstly I must say a huge thank you Richard (DickieG) for all your sterling spannering and help today. The engine is now in and very little work is left before the finges get crossed in earnest and the key is turned. Just the radiator left to fit along with some small items, not forgetting coolant and oil and then we'll know if the car does actually live

Here's a few pictures of the moemntous occasion.

Richard beginning the careful guide of the engine home.

A bit further in!

It's a tight fit

I wondered if it was actually necessary to remove the engine mounts complete, the fuse box and ABS block but it surely was. To get the engine this far, the crank pulley had to come off

Getting close now

Nearly done!

And one very happy Citrojim

A brilliant days' work and Richard, you're an absolute star

Post by **admiral51** » 31 May 2009, 21:07

Excellent work Jim and Richard looks like a day well spent

Dont worry Jim we will all have fingers crossed waiting for the first key turn

Colin

Post by **myglaren** » 31 May 2009, 21:15

Nice going boys! That is certainly a very tight fit Jim.
Hoping it fires up nicely and behaves itself for you.

DickieG · Post by **DickieG** » 31 May 2009, 21:59

It was a very enjoyable, productive day (helped along by a couple of excellent Bacon rolls made by Val) and so good to push the project that little bit further towards completion, as Jim states its now just a few hours away from the nervous moment of turning the ignition key

BTW Jim I spotted your Activa on the way home (I drove straight past it on the way there without noticing) well its not easy to recognize one of your previous cars especially when its red

Deanxm · Post by **Deanxm** » 31 May 2009, 22:09

Does look like a snug fit in there

and the weather was on your side too,
Good luck for the big day Jim.

D

XantiaMan · Post by **XantiaMan** » 31 May 2009, 22:43

Pah, looks like Richard was doing all the hard lifting work what did you need an engine crane for

Nice work chaps, be interesting to see it all working!

MikeT · Post by **MikeT** » 31 May 2009, 22:49

This is so good to see! Congrats everyone involved.
I think Jim's expression says it all $\:D/$