Xantiaman's Blog

XantiaMan · Unread post by **XantiaMan** » 17 Oct 2009, 20:57

Xac wrote:With the engine out it should make splitting the heater matrix end much easier.
I'm thinking it might be an idea to split it now (assuming the matrix hasn't been done recently) simply to make it easier should you need to do the matrix in the future.

If it aint broke... and all that.

Unread post by **CitroJim** » 17 Oct 2009, 21:07

That's a fair looking turbo Gareth and it looks a lot bigger than the standard one. Hope there's room for it when the engine goes back in!

On the heater matrix connector, it's a good idea to try a gentle removal but not go too mad on it but if it's freed now and well greased it will make it easier should it need to have a matrix in the future. I recall it was OK in my ownership but a dose of Forte might not be a bad idea as a preventative.

Weather looks good for Monday Gareth

XantiaMan · Unread post by **XantiaMan** » 17 Oct 2009, 22:05

CitroJim wrote:That's a fair looking turbo Gareth and it looks a lot bigger than the standard one. Hope there's room for it when the engine goes back in!

On the heater matrix connector, it's a good idea to try a gentle removal but not go too mad on it but if it's freed now and well greased it will make it easier should it need to have a matrix in the future. I recall it was OK in my ownership but a dose of Forte might not be a bad idea as a preventative.

Weather looks good for Monday Gareth

The housing sticks out about half an inch more closer to the chassis leg, but still plenty of space IMO, you can see from the picture looking down that there is about 3, maybe 4 inches of gap between the compressor housing and the cam cover, which itself is not right up against the chassis leg.

The inlet hose will need a little trim to fit under the DV.

The compressor wheel is 6mm bigger at the top part (the bit you see) and at the wider bottom section, 3mm bigger. Its was easier and cheaper to use the Rover housing as it didnt need machining. The back part of the housing on the turbo did need machining to fit.

All this, for a bargain price of £110 which included balancing aswell, it was very rude to not have this done with the engine out

Its a little bit more than a 'Stage 1' turbo upgrade. The compressor side will run good to 18psi, if a bigger turbine was fitted it would easily flow enough for 300bhp from what i have been told and still be driveable.

This all gets fitted some time tomorrow, primed up ready to go. I need to look into the manifold nuts, and may just double them up to lock them in place as i cannot find a suitable threadlock to take the heat.

Xaccers · Unread post by **Xaccers** » 17 Oct 2009, 23:56

XantiaMan583 wrote: If it aint broke...

...it probably will when you need to remove it with the engine in place and poor access

Murphy's law and all that

XantiaMan · Unread post by **XantiaMan** » 18 Oct 2009, 20:09

Managed to refit the turbo today, so its just the clutch to be fitted and then engine back in. It was not plain sailing!

Firstly, i cleaned up the exhaust manifold. It was lightly pitted on the face, so i used some 80 grit on a block to clean it up.

Then same treatment for the head ports, they cleaned up well, then a wire brush on the threads.

No copper grease on them, just a bit of WD40 on the nuts to ensure they went on smoothly. Then the new gasket, it only goes on one way.

Tightened up evenly and went over them 5 times to ensure none were missed out, then doubled up the nuts to lock them in place. That should stop them loosening off in service.

Next, the turbo needed to be fitted onto the manifold. There is a sealing ring that fits into a groove, its a fiddle so i used a flat bladed screw driver to hold the ring in place whilst the turbo was offered up. I checked to ensure the ring had gone into the slot properly, but it can only go in one place or the turbo wont sit flush.

Again, no grease just a bit of WD to help along the way.

I started to enter problems with the actuator. It seemed to be in the wrong place. The Rover housing was drilled for the actuator, and after much faffing around it was found the compressor housing was slightly misaligned, so needed moving back anti clockwise about 1cm, then it was spot on.

Everything has to go on in sequence, actuator first, then oil drain, water feed pipes. Oil feed goes on after the huge heatshield.

Next problem was the dump valve diaphragm was split. Being in such a difficult place to access once refitted, i opted to make up an aluminium blanking plate in its place. Came out ok!

Then, the turbo outlet pipe. The outlet on the compressor housing was a fraction too long. As the rubber piece that fits over it has a step on the inside, it can only go on so far.

After much deliberation i took an easy route, and removed a hose from the Maestro which was a perfect fit, and allowed the top outlet to be bolted in place.

Then, the turbo inlet pipe. This needed a jiggle, but its now in near enough OE position as can be seen from the pictures.

So, thats that saga completed! All the hassle would of been saved if the original housing was machined, but never mind, as it cost me very little to get done.

Tomorrow, it will be fitting the clutch and gearbox back on, and then refit into the engine bay! Looking forward to the day, although i have a rather serious issue to deal with as well, which has meant we can no longer purchase the 306

But, time will sort that one out. Be much happier once the Activa is up and running again.

Unread post by **CitroJim** » 18 Oct 2009, 20:25

Good progress Gareth

So, clutch and gearbox back on and engine back in tomorrow then

I'll be there, bright and early all ready to go. Anything else, apart from what I already know about to bring?

A good day of work should see you up and running again...

Citroenmad · Unread post by **Citroenmad** » 18 Oct 2009, 20:44

Very good progress, should go nicely shouldn't it 8)

Your a very handy person to have around Jim, could do with you around here

XantiaMan · Unread post by **XantiaMan** » 18 Oct 2009, 20:53

CitroJim wrote:Good progress Gareth So, clutch and gearbox back on and engine back in tomorrow then

I'll be there, bright and early all ready to go. Anything else, apart from what I already know about to bring?

A good day of work should see you up and running again...

A torque wrench off the top of my head. Got 75W 80 oil for the box assume thats the right one? Its stuff i had left from the TD. Did you make a special tool or are we going to blag it ?

Let me know what sort of time you will be arriving. I will be up early for the young man but hopefully making a start on removing the old gear linkage. Kettle is waiting....

KP · Unread post by KP » 18 Oct 2009, 21:29

Looking good there Gareth.

i do always now wonder on seeing these pictures if a much shorter air inlet route could not be formed on our cars to increase pickup should a bigger turbo want fitting?

On coupes there has been a straight induction pipe mo for ages now, which is as it says, a short 20cm distance, if that, from the top of the filter pipe to the compressor inlet. Now i cant see where it would go other than in the wheelarch...

wonder if an up an over job from where the fusebox is could be used instead, or flip the engine round would be the best way to go

Anyway i digress

Hope the fiddling around will be worth it

Are you planning on getting it on a RR after all the work??

Dont worry about the slug 306, theres plenty of ZX's still out there and they are cheaper and usually been a bit less raced around as ell in 1.9td form as well

Unread post by **CitroJim** » 18 Oct 2009, 21:38

XantiaMan583 wrote: A torque wrench off the top of my head. Got 75W 80 oil for the box assume thats the right one? Its stuff i had left from the TD. Did you make a special tool or are we going to blag it ?

Let me know what sort of time you will be arriving. I will be up early for the young man but hopefully making a start on removing the old gear linkage. Kettle is waiting....

OK, Torque Wrench added to list

75W/80 is correct.

Special Tool fabricated from guesswork

Got a file just in case?

I reckon I'll be there about 9:30 'ish. Will give you a bell when near. Guess best to come up the A47 and then down the Dereham Road to join the ring road. I'll have Tom Tom guiding me...

Off to bed now. Big day tomorrow...

Keep that kettle hot!

XantiaMan · Unread post by **XantiaMan** » 18 Oct 2009, 21:44

CitroJim wrote:
XantiaMan583 wrote: A torque wrench off the top of my head. Got 75W 80 oil for the box assume thats the right one? Its stuff i had left from the TD. Did you make a special tool or are we going to blag it ?

Let me know what sort of time you will be arriving. I will be up early for the young man but hopefully making a start on removing the old gear linkage. Kettle is waiting....
OK, Torque Wrench added to list 75W/80 is correct.

Special Tool fabricated from guesswork Got a file just in case?

I reckon I'll be there about 9:30 'ish. Will give you a bell when near. Guess best to come up the A47 and then down the Dereham Road to join the ring road. I'll have Tom Tom guiding me...

Off to bed now. Big day tomorrow...

Keep that kettle hot!

Lol, i can get a file if needed... Glad the oil is right, its not cheap!

There are numerous ways to get to me, depending on time of day and mood

I would advise getting on the Norwich ring road as you suggest, but go down Hellesdon Hall Lane, takes you into the back of Drayton and then you are virtually there.

Don't worry about lunch we are going out for that one...

Unread post by **CitroJim** » 18 Oct 2009, 21:51

XantiaMan583 wrote: I would advise getting on the Norwich ring road as you suggest, but go down Hellesdon Hall Lane, takes you into the back of Drayton and then you are virtually there.

Noted!

XantiaMan583 wrote: Don't worry about lunch we are going out for that one...

Excellent!

davetherave · Unread post by **davetherave** » 18 Oct 2009, 22:31

Ive got a day off 2moro so if you need a hand (probably more physical help than mechanical though!) ill pop across in the Xm!

Unread post by **CitroJim** » 19 Oct 2009, 04:57

davetherave wrote:Ive got a day off 2moro so if you need a hand (probably more physical help than mechanical though!) ill pop across in the Xm!

That'll be great Dave and brilliant to see the XM!

XantiaMan · Unread post by **XantiaMan** » 19 Oct 2009, 07:16

CitroJim wrote:
davetherave wrote:Ive got a day off 2moro so if you need a hand (probably more physical help than mechanical though!) ill pop across in the Xm!
That'll be great Dave and brilliant to see the XM!

Holy crap Jim you were up early!

Dave, your welcome to come over but parking is going to be an issue, Vicky's Dad is here as well!