I returned to the job on Saturday about noon and only got wrapped up (that is, car been running over an hour and clearing up kind of finshed) Sunday evening. I'd thought I might have it naild by end of Saturday
o well, blew the hell out of my weekend..Anyway, it is done and has done the 20 miles home as well, I'd missed driving it for 2 weeks - aaagh I am addicted to Citroens..
My word Jim, thanks for the "good luck with the manifolds" , that exhaust manifold is a genuine nightmare! I think that should be used to replace prison. I wouldn't wish that on anyone.
Also my phone died so it's getting sent back for warranty, and I'm on the backup phone that has a dreadful quality camera - it doesn't seem to like focusing on anything at all.
Here's the only few pictures taken today:
All the hard and heavy bits back in, I painted the rocker cover in gold high temperture paint I'd got originally for brake clipers until I went with green for those.. I thought the gold would cap it all off with the new rocker cover seal of course...
WP_20171203_004 by Graeme McNulty, on FlickrThe dreadful camera makes the gold look like lego brick yellow! I assure you it's gold to (sort of) go with the Mk1 Xantia paintwork.
And a few blurry pics of the engine with the final bits on:
WP_20171203_006 by Graeme McNulty, on Flickr
WP_20171203_007 by Graeme McNulty, on Flickr
WP_20171203_010 by Graeme McNulty, on FlickrI replaced the manifold gasket of course, new thermostat, diesel filter, a good few replaced hose clips. I also fitted the timing belt idler and tensioner I'd bought last year with the belt but didn't fit at the time. The tensioner was alright apart from the battle with the spring-plunger. But the fixed roller was a different shape to the original. It has the same roller and the same fixings but has a massive back plate that when fitted, well, didn't. It fouled on the tin plate thing between the block/'head and the stuff on the timing belt side. It also fouled on the step between the idler and the diesel pump.
WP_20171202_002 by Graeme McNulty, on FlickrAnyway, in the end I simply cut the new roller back plate to fit.
My god, I must be dumb or the Haynes BOL was written by satan. See, the special tool you are recommended to make to hold the tensioner plunger in for refitting works well, trouble is that when you have to actually fit the engine mount lower support back in place, you can't actually do that with the tool in place because one of the two holes used by the tool has to have one of the bolts already in it to fit in the car again! It's too long a bolt to fit in after it's all in place and the tool is removed. No amount of jacking up the engine or lowering allows it to go in and taking out the 'tool' sees the spring plunger shot out, bang off the floor and spring across the room
So I had to do my own method of fitting it back without the tool that was made. I still kept the tool, you know, just in case 
Then the terrible exhaust manifold refit
](./images/smilies/eusa_wall.gif "Brick wall"){kind=small}
Seriously, next time ( ) I will have to split the turbo off the manifold and refit them all one by one. They'll come out ok but going back in is NOT simply reverse of removal. Those darn manifold studs 
my zen was not on this time and I kept wondering 'what would Jim do'.. probably a better way! Note for the future: exhaust port #4 has to have the end and upper studs in place in the head before it all goes back in. All the other studs can slowly be refitted in the head with it all in the car, but the two at the end need to be in already (also the inch-long spacer of each needs to slide on WITH the manifold not after as that is impossible with the turbo in the way) otherwise...... joy.Anyway the main thing was the head skim and refit and that was fairly straightforward apart from my newly- purchased torque angle gauge falling apart on cylinder head bolt number 8 (out of 10) but you just have a calm chuckle to yourself...
I replaced the fuel pipes because the diesel supply pipe to the filter housing and the one from the filter to the pump were both no longer made of rubber and were now made of stone. The diesel return pipe from the pump has been replaced in the past by someone, badly as it wasn't routed correctly and was too short to properly accomodate the movement of the engine on its mountings. It was also now made of stone and even more solid then the factory pipes mentioned.. All replaced, new clips, a one way valve fitted and a totally cleaned filter housing.
Finally back together and running and I have lost several screws. I'm usually very good at not losing screws as I use several magnet dishes but this time somehow I lost both the M5 screws that hold the air intake pipe to the bracket on the inlet manifold.
Also! everything went on perfectly (apart from the nonsense with the TB tensioners and manifold) but that darn breather pipe that goes from low down on the oil filler column up to connect to the rocker cover really has to be fitted BEFORE the thermostat housing, glow plug connector, diesel injector pipes and fuel pipe to the pump, but hey, you learn....
I enjoy doing this!
