Citroen C2 1.4HDI - Clutch Change

[mickthemaverick]

You may find this a good idea: https://www.ebay.co.uk/itm/326744265472 ... R6S_zvyfZg

[xantia_v6]

If the 2mm movement is at the end of the shaft, then I wouldn't worry, the pilot bearing in the crankshaft should handle that.

[Gregca]

Me again - this job is grinding away very slowly. Weather and waiting for parts. I decided to replace the crankshaft oil seal even though the existing one looked OK. So the flywheel came off. I have fished out the old seal and I am now about to refit the flywheel. Does anyone know the bolt torquing details? I have a feeling it is a combination of torque value and additional angle. It would be great if I had the full set of torques for:
Flywheel bolts.
Clutch pressure plate screws/bolts
Bell housing, Starter etc.
Track rod ends.
Hub swivel joint (3 bolts) and pinch bolt (1)
Any other bolts???

Right now the flywheel and clutch bolts are my priority.

I assume that angular tightening requires a protractor and some marking. I have contemplated making a cardboard template with the two angukar lines marked with a small hole to put over the bolt. Has anyone done this or similar?

[shtu]

An angle gauge is cheap if you really want, but the easy way is to tighten to the stage that you need to add angle, and draw a line on the bolt head. It's dead easy to eyeball 30, 45, 60, 90 degrees, and it doesn't need to be degree-perfect.

[xantia_v6]

You will find torque specifications in https://mega.nz/file/2poV1I6T#lKlbXOc5r ... NxmzMty--M

[Gregca]

Thank you I also found this manual but it is a bit vague for my liking. No instructions. A few scanned pages from the Haynes bible would be more helpful....

[wurlycorner]

A few relevant pages from what you mention above.
EDIT: The engine pages below are from the PETROL engine section of Haynes. See later post for the Diesel engine pages.
Really do recommend buying a copy for yourself.

[Gregca]

Thank you for the specs.

[Gregca]

Out of interest I found this detailed information for tightening the flywheel bolts. I really wonder if any garage mechanic has read these specs and actually followed them? This is one of the reasons I prefer not to trust my vehicles to garages. The Haynes manual does not go this far....

1.4 HDI DV4TD (8HX) - Flywheel

Stage 1 25 (Nm)
Stage 2 (Loosen all)
Stage 3 8 (Nm)
Stage 4 17 (Nm)
Stage 5 75 (Degrees)

[wurlycorner]

Sorry - I was doing that on my phone and posted the pages from the petrol engine section (you'll see that at the top of the pages).
These are from the Diesel engine section.

Mechanics in non-dealer garages won't access the official PSA service information, but will refer to something like 'Autodata' for specs and information when needed.
That information should reflect the correct manufacturer torque specs - but they will only do that for 'critical' bolts (e.g. cylinder head bolts). Otherwise yes - they usually won't bother and just use generic torque specs, 'experience', or 'FT'.

[Gregca]

Latest instalment in the clutch renewal saga - Today I just managed to join the gearbox and engine together (not all the bolts but enough). I have the bottom snug but the top would need pulling on tighter. However I currently see no point as I have just tried the clutch release lever and I can easily move fully backwards and forwards! It feels as if it is not pressing on the clutch pressure springs.

Where have I gone wrong? - Please do not say "Should not have started"

Yesterday I carefully greased the input shaft splines with the special extra sticky grease which I had to order as i did not want to use the wrong stuff. I did not grease the plastic release bearing as instructed by the LUK data sheet. I attached the clutch to the flywheel and tightened it 20Nm. Small amount of grease in the pilot hole. I have replaced 4 oil seals. 3 on the gearbox and the rear crankshaft. I have been totally meticulous and now today in between downpours I struggled but succeeded in getting the gearbox lifted (no hoist only wood, sweat and now nearly tears).

So what I have done wrong? I know that it will have to come off and I will have to do something but what?

Currently sat in the kitchen with a mug of strong tea and resting my aching back......

No plans to look at it today.

[Steve Walsh]

Is it possibe to get a small mirror and torch and look through the opening for the lever to check it is located on the pivot and bearing

[wurlycorner]

Well done making more progress, I'm sure it's very frustrating it not having worked out yet...
Aside from the oil seals (which won't be relevant to the problem here) what other parts have you replaced?
Did you compare the old clutch and release bearing with the new, to confirm they matched correctly, before fitting? (long shot/unlikely, but possible that you've got the wrong parts).
Could you upload some pics or video to show us please?

[Gregca]

Good to know that I am not alone with this quest. I have been stewing on it overnight and have been thinking about it. I am going to try to get my fibre USB camera through the lever opening and look if there is anything obvious. I am wondering if the shaft is not centrallised and pressing on the clutch spring leaves (doubtful). Also if the bearing came off the shaft. Etc. I will also double, treble check I have the correct parts. The clutch fitted well as did the pressure plate and the bearing so I am sure they are correct. I will be something stupid I am certain, me, it must be old age.

[Steve Walsh]

Keep us informed, Sure you will sort it out