Our Latest Project: 2005 55 C5 HDi VTR

Tell us your ongoing tales and experiences with your French car here. Post pictures of your car here as well.

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citroenxm
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Re: Our Latest Project: 2005 55 C5 HDi VTR

Post by citroenxm »

lexi wrote:I have a full set of chimney sweeping brushes here Paul for that soot. :lol:
I hope you get a nice runner and some big miles out of her when done.
Shes too good for me to keep once finished over all. So she will be a seller..

lexi
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Re: Our Latest Project: 2005 55 C5 HDi VTR

Post by lexi »

Ah, well good luck in making a few shillings on her. 8-)

citroenxm
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Re: Our Latest Project: 2005 55 C5 HDi VTR

Post by citroenxm »

Shouldnt be bad.. new clutch and dmf at 100k .. new turbo now .. ill also put cam belt and water pump. . Drop links.. two rear tyres.. increadably tidy for the age and miles to be honest and everything works.

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Re: Our Latest Project: 2005 55 C5 HDi VTR

Post by citroenxm »

So on an update ive temperary fitted the turbo back on so I can use the car.. but with thanks to richardw and his supeior knowledge on 1.6 hdis over me I have plumpt for buying a new gaurenteed Garrett cartridge replacement for the turbo. The broken vanes concerend me.

I can then see if I can find out why the turbo makes a rattleing noise over 3k and where the soot comes from...

Thats all for now..

citroenxm
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Re: Our Latest Project: 2005 55 C5 HDi VTR

Post by citroenxm »

The turbo cartridge, cam belt kit and water pump have all arrived now..

so between wet weather, an xm project and work I shall get this all done.. slowly.

however none of this stuff is hard on these 1.6 engines.. the belt is like old school xud and there are timing pins to lock the cam crank and fuel pump... the 1.6 doesnt use a lift pump.. the engine driven pump is just that.. so it needs manually priming.. and its timed too..

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CitroJim
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Re: Our Latest Project: 2005 55 C5 HDi VTR

Post by CitroJim »

You're starting to sell the 1.6 engine to me Paul :)

citroenxm
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Re: Our Latest Project: 2005 55 C5 HDi VTR

Post by citroenxm »

Managed to do a bit on this today, and got the turbo off again..

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Heat shield already removed, the DPF pressure sensor pipe needs removing from the exhaust for heat shield removal.. I had already removed previously..

So, firstly, remove the intercooler pipes to gain some space, the plastic pipes are held on by two 10mm bolts.. this then gains more room..
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Now the exhaust cat/dpf bracket needs slackening so the CAT can be move away slightly from the turbo outlet
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Now to aid turbo out to intercooler pipe removal, the air flow pipe assembly on the left needs removing..
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Its held on by three 10mm bolts.. slacken three connecting pipes of choice, and remove the three bolts.
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Top one is the middle in the pic above..

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The lower one, and round the side, above the PAS Pump pully, the third one:
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Once thats away, the plastic cross pipe can come off a bit easyer..
Slacken the left 10mm bolt and undo and remove the right hand bolt, the pipe has a pop clamp at the other end on the C5, left it and then remove..

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Now the Oil feed and return pipes can be removed, the feed pipe bolt is an Allen Bolt 10mm head.. watch for the two Copper seals..
The Oil drain is just a rubber drain hose! Dont forget also to remove the Wastegate vaccum accumilator feed pipe..
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Remove this inverted bolt too from the support bracket - an 8mm spanner also sufice to undo it..
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Then the unit can be undone from the manifold... and are 4x11mm bolts..
Two at the top:
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And Bottom:
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And wangle the unit out, BUT be carefull of the Oil Feed pipe, and work round it..

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So, as previously shown there was tips broken off the compressor wheel vains, and I was also concerned about Exhaust soot leakage, but I beleve is wastegate setting on that more then anything..

Next to dismantle the unit to fit the preset and balanced Cartridge.

citroenxm
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Re: Our Latest Project: 2005 55 C5 HDi VTR

Post by citroenxm »

So, we have the unit removed.... then we need to remove the Turbine and compression houses...

Pop this spring clip off the wastegate spigot, and then remove the wastegate controller unit from the bracket..
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Remove the 5 10mm bolts as above, and the exhaust houseing will come away nice and easy to reveal the internal wastegate setup...

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Wastegate open:
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Wastegate closed:
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Now the turbine house needs to come off the other side.. remove the 4x 8mm bolts holding it on...
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Give it a light and small tap, and it should come away, look out for the small edge seal..

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Clean the edge of the Turbine house up, the Turbo Cartridge ONLY GOES IN ONE WAY! Theres a small roll pin that fits into a hole in the turbine house, but also at the same time you need to line up the wastegate lever control with the wastegate vanes... and refit the 10mm bolts.

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The compressor houing goes on in any position for application setup, in this instantce the outlet points out backwards towards the engine, however the exact position wont be easy to set untill outs mounted on the manifold again...

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Fit the new small edge seal to the turbo, and then offer up the compressor house roughly in the correct direction...
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Nip the 4x bolts up but slack enough for the house to rotate, when its then fitted to the car it can be placed in the correct position and tightend up ..

Refit the Wastegate vaccum accumilator, and fit the arm on, and press the spring clip back on. This unit needs the wastegate lever stop adjusting... which I need to learn to do..

Refit as removal in reversal, though I couldnt do this today, by the assembled stage it absolutley pea'd it down!

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CitroJim
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Re: Our Latest Project: 2005 55 C5 HDi VTR

Post by CitroJim »

Paul, this is excellent :D The basis of a useful guide for turbo replacement/overhaul!

It needs to go in the Wiki ;)

citroenxm
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Re: Our Latest Project: 2005 55 C5 HDi VTR

Post by citroenxm »

Small update, got round to swapping the oil feed pipe as I had over stretched the pipe and damaged the internal seal...

Not bad to do, but the cat/DPF needs to come away from the block to get at the other end of the feed pipe. While I was in there, I removed the oil strainer from the feed pipe...

Un hook the clamp from the exhaust to turbo outlet... and then undo the two 13mm cat/DPF bracket bolts as seen in earlyer pics and the unit just comes forward enough to get at the 10mm banjo bolt...

So she is up and running again now, next job is Cam belt and water pump! I had a look briefly, and it looks like I might have a dreadded Caliper corosion on the rear to deal with...

TBC....

citroenxm
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Re: Our Latest Project: 2005 55 C5 HDi VTR

Post by citroenxm »

Progress tonight. the car was waiting for Cam belt kit and waterpump.. so I set about this tonight... and.. NO messing, from start to belt and water pump off, 50 mins!!! Once the engine is supported underneath, the engine mount can be loosened, and removed. Three T50 torx bolts.. and a 16mm bolt through the torque link... lift it out. The mounting block on the side of the head needs to come away too, 4x 16mm head bolts, but it wont come away untill the upper cam belt cover is off... The cover is held on with a number of 7mm headed screws.. and the wiring harness is attached to the cover via tie wraps, snip the ties away... take the top cover away and then the mount block, then you have brilliant AMAZING access to the lower half! The crank bolt is 18mm size, and not amazingly tight, but I still used the starter to crack the bolt... Crank pully is nice and loose and not a tight fit... behind the pully is a guide plate with holes and one circular hole, its needs to line up with the corresponding point behind it in the block, the cam is timed and on these as the pump on the engine IS A PUMP its also timed, and has a timing hole!!

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You can see the Cam timing hole and coresponding hole in the head!!

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Fuel pump pully on the left, with an allen key holding time, and looking closely at the crank I put a "Screw" in to hold crank timing reference!

Look at all the room!

The tensioner is the eccentric type, like 2.0 hdi ones... so no suprises there..

Water pump a number of 8mm headed bolts again nice n easy, and it fell away and left no gasket on the block face..

Fit it all back
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NOTES: For a couple of points, theres a Belt "Holder" blow right of the crank pully, which helps hold the belt up against the crank sprocket.. I also removed the crank sensor too, but Im not sure it was essential, its only 1x 10mm bolt.

Ill take some pics of the covers and mounts tomorrow while I reassemble.

wurlycorner
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Re: Our Latest Project: 2005 55 C5 HDi VTR

Post by wurlycorner »

That looks like a delightful piece of p**s to do - result! (but still well done getting it done in that time 8-) )

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CitroJim
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Re: Our Latest Project: 2005 55 C5 HDi VTR

Post by CitroJim »

wurlycorner wrote:That looks like a delightful piece of p**s to do - result!
Looks even easier than the Activa TCT :D

Good to see...

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Re: Our Latest Project: 2005 55 C5 HDi VTR

Post by wurlycorner »

I found the cambelt on my Activa a PITA :-k access to one of the tensioner bolts and removal of the lower cam cover was s**t, from what I recall... (I ended up cutting the bottom of the lower cam cover so I could pull it off :oops: of which, all these years later I have now got a replacement on order at the pug dealer! 8-) ).

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CitroJim
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Re: Our Latest Project: 2005 55 C5 HDi VTR

Post by CitroJim »

Yes but a TCT is much less of a PITA than say, a 1.9TD or 2.1TD...