Rust inside engine bay

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dave_xsara
Donor 2021
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Rust inside engine bay

Post by dave_xsara »

Was looking at my car to see if I could determine where a vibration would be coming from and noticed this rust inside the engine bay.
It is close to where the strut is mounted.
Xsara - Engine bay, driver side
Xsara - Engine bay, driver side
Is this a big problem for the integrity of the car or can it be fixed? If so, what would be required to fix it in terms or work?

Getting a bit irritated with the car now. Ever since I put in the new suspension front and rear it has been a procession of vibrations, rattles and suchlike requiring attention. So far they have been straightforward to resolve - loose strut, radiator bushes, and airbox housing not seating correctly.
The sun visors are vibrating now as well, but I can't see what would be causing that - again just noticed this since the suspension fixed.

I might have to record the vibration and put it up here to see if any of you can think of what to check. Looked all over the front, double checking the critical components and they all seem fine. Got a mechanic to check and he could not locate it either. Very odd, doesn't happen going over bumps etc in the road i.e. doesn't appear to be suspension components, but if you hit a divot in the road at around 50mph there is a vibrating noise that sounds like a hard plastic vibrating at a high frequency against the body.

Seems like tightening up the suspension has somehow sent shockwaves through the chassis resulting in all this hassle!!!

However, despite the above, the car handles like new and is lovely to drive again. Really can't afford (or want) to sell it now that this amount of effort has been put into it.


Anyhow, what about this rust?
lexi
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Re: Rust inside engine bay

Post by lexi »

If you can't put a screwdriver through it, just get in with a wire wheel, brush or whatever. Then treat with rust eater, prime and paint.
sparksie
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Re: Rust inside engine bay

Post by sparksie »

lexi wrote:
27 Mar 2018, 21:37
If you can't put a screwdriver through it, just get in with a wire wheel, brush or whatever. Then treat with rust eater, prime and paint.


seconded!
But do it soon.
It won't take long for that to dissolve into thin air, especially with all the salt water it's most likely been exposed to in recent weeks, thanks to the frosty weather
ekjdm14
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Re: Rust inside engine bay

Post by ekjdm14 »

"Third-ed"! Definitely lay into it with some sort of abrasive, wire wheel/flap disc & knock all the heavy stuff off, treat with a rust killer solution, then either prime/paint body colur if you care about looks or cover with a good layer of hammerite and underseal otherwise.

Would be prudent to pull the arch liners out and check on the underside as well, even if there's no corrosion there's likely a couple of good handfuls of perma-damp salty mud/gunge up behind them waiting for a stone chip on the end of the sill.

Also, speaking of arch liners & underbody plastics in general. I know it's hard bordering impossible to diagnose a noise through a textual description but it does seem likely given your description and the recent suspension work that there could be something not quite fixed/aligned properly under there & getting forced onto a tyre in certain conditions. I'd look at edges of plastic panels for any signs of scuffing/check for fit etc. Also ensure the engine mounts are in good shape and the exhaust is properly aligned and all hangers intact as these can cause confusing vibrations through the car in seemingly unrelated places.
dave_xsara
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Re: Rust inside engine bay

Post by dave_xsara »

Thanks for all the replies.
Yes, I'll get stuck into that repair soon.

In relation to the vibration, I'll stick up a video of the noise at the weekend. We've already checked the exhaust and it is not touching on anywhere. Engine mounts looked okay too.
It seems to be originating from directly in front of the driver position. I was wondering if it was related to the bulkhead as as everything else seemed okay - although we must have missed something.
ekjdm14
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Re: Rust inside engine bay

Post by ekjdm14 »

Video would be helpful yes, I don't think that rust looks bad enough to cause a vibration issue noticeable to the driver. If it were that bad I'd expect to see big frilly holes.
dave_xsara
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Re: Rust inside engine bay

Post by dave_xsara »

I've not been on a loong enough journey to obtain the noise and record it.
However, searching YouTube has brought me to the below video.

Listen to it from 7:30 into the video and you will hear exactly the same noise as my car is producing. This guy diagnoised the problem as a seized caliper.
However, I've realised that the CV boot has a split so maybe it is causing the issue. This might also explain the vibrating in the cabin of the dash and the sun visors.
I'll record my own video anyway and write up the conclusion.

dave_xsara
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Re: Rust inside engine bay

Post by dave_xsara »

Looks like it is the bottom pulley that is causing the problem. I've been unable to record the noise whilst driving, but at idle there is a distinct noise coming from behind the wheel on the drivers side. It increases with engine revs and then goes away as the revs go higher.
Timing belt was only changed a few months ago, so it looks like it was something that was overlooked during replacement.
ekjdm14
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Re: Rust inside engine bay

Post by ekjdm14 »

Hope the pulley is the root cause, although if it's similar to that guy's problem I'd definitely be looking into CV joints & wheel bearings too. Black has a very similar dull clicking/tapping vibration come to think of it, not at all unlike a structurally failed tyre as he says & I've got the CV joint in stock now but since getting that the wheel bearing on the same side has developed a drone like a 747 landing so could equally be that. (all the necessary is to be sorted on Black over the coming months, she's been a great car for a year of reliable motoring & much deserving of a thorough refresh and gearbox rebuild when White is deemed fit to take over as daily).

There's a company on Ebay who sell brand new CV joints and complete driveshafts for really good prices, I've had a few of each from them now and can thoroughly recommend J&R to anyone needing driveline bits... Here's a listing for your car I believe, £15 delivered for a joint kit J&R link
dave_xsara
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Re: Rust inside engine bay

Post by dave_xsara »

Thanks - I'll store off that link.
Hopefully just the bottom pulley to replace. What is the correct tool for locking the flywheel? Are the tools specific for each engine or are there reasonably priced alternatives that cover a range of engines?
ekjdm14
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Re: Rust inside engine bay

Post by ekjdm14 »

Now this is one area I'm not 100% of on the HDi, as far as i know though the flywheel can be locked for pulley removal/fitting via a 6mm pin/drill bit/allen key behind the starter similar to the XUD.

Another method of removing the pulley bolt would be to put the car in top gear & block the brake disc from turning with a screwdriver through a vent channel. Not the correct way but it's worked a few times for me as a "quick & dirty" workaround. Hopefully you have a suitable size allen key available though, assuming i have my thoughts straight & it is locked in this way.
dave_xsara
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Re: Rust inside engine bay

Post by dave_xsara »

Thanks - I'll take a look into that. I've loads of allen keys, so I'll check it out.
dave_xsara
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Re: Rust inside engine bay

Post by dave_xsara »

Pulley has been replaced. Engine is running so much better now. The original pulley was in since new, so 17 years is a good return. It secure replacing anyway so it was not a wasted effort. A lot quieter at idle.

However the bloody rattle is still there. It has been less prevalent now than previously but still there nonetheless. We'll l take a closer look at the cv but I'm still unsure that is the issue.
dave_xsara
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Re: Rust inside engine bay

Post by dave_xsara »

Does anyone know the correct name or part number for the handbrake cable bracket that is attached to the inside of the rear hub. It is located where there outer shield of the cable terminates.
I need a new one, but can't find what I should be getting.

Thanks.
dave_xsara
Donor 2021
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Joined: 24 Nov 2010, 22:35
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Re: Rust inside engine bay

Post by dave_xsara »

Actually, I think I've found it (or something similar).

https://www.ebay.co.uk/itm/GENUINE-PEUG ... 2345189157

I've sent this seller a message to ask if it will fit (actually now don't think it will as I have a feeling the Xsara might clamp the brake pipe to it as well), however does anyone know roughly how much these cost new from the dealers - or what the actual Part number is?

Thanks.