Xantiaman's Blog

XantiaMan · Post by **XantiaMan** » 12 Oct 2009, 09:16

I've been quite busy this weekend on the Activa as can be seen on this thread -

http://www.frenchcarforum.co.uk/forum/v ... hp?t=28403

I did make an interesting discovery this morning. As suspected, the gasket has blown to bits near the cambelt end, and the nuts holding the manifold were loose. The other side with tight bolts survived better. It may of been incorrect torquing that caused the failure?

Reading a few pages back, for a while now i suspected the actual manifold was blowing and not just the gasket. Well i was right

The manifold has cracked in two places around the turbo mounting flange, its quite bad actually and will account for the whistling noise i have been hearing.

So luckily thanks to obtaining a spare engine i have a very good manifold too.

The clean up process begins later on. I will be ordering gaskets today and my new turbo should be ready by the end of the week. I am also going to fit the low miles box and clutch from the other engine. Then its fit it all back together with the final lining up process of the clutch release bearing left in the capable hands of Jim'll fix it 8)

CitroJim · Post by **CitroJim** » 12 Oct 2009, 09:26

Excellent Gareth

I'llbe interested to see the state of the old manifold.

XantiaMan583 wrote:Then its fit it all back together with the final lining up process of the clutch release bearing left in the capable hands of Jim'll fix it 8)

No worries! Do you or are you in a position to set a date for this so that I can book leave to come over and see you?

XantiaMan · Post by **XantiaMan** » 12 Oct 2009, 11:29

CitroJim wrote:Excellent Gareth I'llbe interested to see the state of the old manifold.

XantiaMan583 wrote:Then its fit it all back together with the final lining up process of the clutch release bearing left in the capable hands of Jim'll fix it 8)
No worries! Do you or are you in a position to set a date for this so that I can book leave to come over and see you?

I'll ave a look at my calender and let you know ASAP mate

CitroJim · Post by **CitroJim** » 12 Oct 2009, 13:07

XantiaMan583 wrote:I'll ave a look at my calender and let you know ASAP mate

Perfect

Any day except this Thursday is OK.

XantiaMan · Post by **XantiaMan** » 12 Oct 2009, 13:20

CitroJim wrote:
XantiaMan583 wrote:I'll ave a look at my calender and let you know ASAP mate
Perfect Any day except this Thursday is OK.

I wish! Won't be that quick! I should get the Turbo back on Wednesday, but will be away until Friday night, so possibly beginning of next week? Mon to Wed i can keep free usually.

Have degreased the engine bay, looking much better, and WD40'ed some connections to prevent water seeping in. I have pics! About to upload.

Gareth

XantiaMan · Post by **XantiaMan** » 12 Oct 2009, 13:38

Some piccychars.

Looking sad

Pre-clean

Hydractive valve, looks undamaged

Engine oot.

Been blowing a while

'New' Manifold has a tiny hairline crack but not serious, yet!

Front of 'new' manifold

Front of old manifold. Oh dear.

Yep, its buggered.

Manifold gaskets, or what is left!

Citroenmad · Post by **Citroenmad** » 12 Oct 2009, 18:45

That must have gotton rather hot at some point, looks a little cooked!

Should be nice when done 8)

CitroJim · Post by **CitroJim** » 12 Oct 2009, 19:50

Gareth,

It may be my imagination but one exhaust port looks a bit white, as if one cylinder is running a tad weak and thus getting hotter than the others. Does this correspond to the port on the manifold showing the cracks?

If it does, I'd have the injectors flow checked just in case that one is a bit iffy. Else that, whilst it's easy, check the valve clearances.

XantiaMan · Post by **XantiaMan** » 12 Oct 2009, 20:20

CitroJim wrote:Gareth,

It may be my imagination but one exhaust port looks a bit white, as if one cylinder is running a tad weak and thus getting hotter than the others. Does this correspond to the port on the manifold showing the cracks?

If it does, I'd have the injectors flow checked just in case that one is a bit iffy. Else that, whilst it's easy, check the valve clearances.

Jim, your not the first to notice this

But, the two end ports where blowing really bad whereas the others were not, so i am making the assumption that the reason for this soot was due to the leaking gases. You can see on the clean port that there has been no leakage from that part. I'll have a look at the spare engine aswell as i remember the ports in that being near enough spotless in comparison.

I could always swop injectors from the low miles lump if concerned.

XantiaMan · Post by **XantiaMan** » 12 Oct 2009, 20:52

Been out and checked, on the spare a couple of ports are clean, the others are dirty but not as dirty as mine. I still think its an issue caused by the gasket leaking and the ECU over compensating for the leak. I will look into swopping the lower miles injectors over anyway as a precaution.

Good news on the clutch, its an LuK one and is still fresh, i understand its OE for some makes. At least its not EBC

The gearbox literally fell off! Very easy to remove.

Would i be right in saying i dont need to mess about with the release bearing, as its still on the pressure plate, and this will be going straight onto mine?

CitroJim · Post by **CitroJim** » 12 Oct 2009, 21:44

Gareth, can you take a picture of the clutch assembly now separated please. Where is the release arm (the bit the slave cylinder works against)?

It's my understanding that a special tool is needed to pull the release arm back into contact with the release bearing on reassembly as it's held in place with a C clip that has to be pulled back into engagement.

It's no problem to make such a tool. What would be useful also is to see how bing the business end of the tool needs to be and then I can make one for you. I understand there is a cruciform cutout in the end of the release arm to accept the tool so that it can be pulled. If you can let me have the dimensions, that would help hugely.

This is a picture of the ML5 clutch.

Is the bearing still attached to the diaphragm? Have the forks on the end of item C slipped out of the bearing?

This is the special tool for pushing the bearing into the diaphragm.

As far as I can see, the new bearing would be hung off the forks and this tool would be used to apply pressure to the other end of item C to pull the bearing into the diaphragm.

Question is, can you reassemble it all with the bearing as is? If so, easy. No worries and we may not need the tool at all.

XantiaMan · Post by **XantiaMan** » 12 Oct 2009, 21:50

The bearing is still attached to the pressure plate. The release arm and forks still on the box. So its the arm that needs clipping onto the bearing on reassembly? Didnt note a C-Clip, may still be on the bearing, i will have a closer look tomorrow, can do pictures as well.

Post by **RichardW** » 13 Oct 2009, 12:18

RE the clutch: The official method is to remove the clutch from the flywheel, then the release bearing from the pressure plate ('just' lever the sping clip out

). Fit the release bearing in the release fork on the input shaft, refit the clutch to the flywheel, mate the box back on, then insert your tool and give a pull on the release fork to re-engage the release bearing to the pressure plate. Presumably this is because lining up the release fork with the bearing would be nigh on impossible - but if you can get it in the right position it should go back in - it came out after all! It will need 2 people though, one to lift the box and guide it back home, and another (with small hands, Jim!) to reach in between the bell housing and box and position the release fork. Unlike the old 1.9TD cable operated pull clutch, you can't position the release lever from outside the box by rotating the release shaft AFAIK.

Caveat - never done it, this is all my understanding from reading the BOL re the 2.1TD. Probably all spherical objects then....

XantiaMan · Post by **XantiaMan** » 13 Oct 2009, 20:32

Took the box of my engine today, again nice and easy. It too has an LUK clutch leading me to believe it is an OE part for the car. The surprise was the condition, it was actually very good with no signs of recent slipping and only very slightly worn compared to my new clutch.

Here is the engine after a degrease. They are not a pretty engine tbh!

And i also cleaned the low miles gearbox

Spare engine is now sold and going to a new home, leaving me with the gearbox as a bonus, and i can now pay for the uprated turbo, result

CitroJim · Post by **CitroJim** » 13 Oct 2009, 20:44

RichardW wrote: Caveat - never done it, this is all my understanding from reading the BOL re the 2.1TD. Probably all spherical objects then....

No, not spheres at all Richard, that's very much my understanding. Agree that with the engine in-situ it might be very tricky to line up the forks but with engine out and my girly hands, you never know

When you're ready for the reassembly Gareth, let me know and me and my hands will come up and we'll then see

Let me know soonest a good day to come up in the week. next week is looking clear at the moment, as is the week after but the sooner we can agree a date the better.

Do let me know the size/shape of the hole in the end of clutch fork so I can fabricate a tool before I make the journey, in case we do need it.

Looking forward to this. Pleased to see the engine looking very clean.

Out of interest, where was the bite point on the old clutch? I can't rightly recall now but interested to see if the bite point may have any bearing on possible wear.

Good work sir!