Suspension sinks on Sundays! C5 X7 that works hard + 206 GTi HDi (and 406 Coupe and 306 HDi). - MattBLancs

[MattBLancs]

Trying to confirm what fixing types I'd need in the alternator,

This one:

Clutch pulley number 1

https://www.ebay.co.uk/itm/255881302348
Looks like splined outer and Allen type fixing in the shaft.

Where as this one looks like... I've not a clue!!

Pulley number 2

https://www.ebay.co.uk/itm/394537577310

Not many second hand ones have lost the plastic clip on cover over the end of the pulley, so pictures of what's within hard to find!

[MattBLancs]

Splined outer and... Too dark to see shaft

https://www.ebay.co.uk/itm/364117855924


Hmm, another weird looking one:

https://www.ebay.co.uk/itm/115751064910

(P.s. £250 for second hand alternator!!! )

[MattBLancs]

Ahhh, a pretty clear image of the weird version, and to be honest I understand it even less seeing this!
https://www.ebay.co.uk/itm/204296686411
Almost looks like two blobs of weld on this image,

Weird version are all on Valeo units, the others are an INA pulley on a Mitsubishi manufactured alternator.

Existing alternator fitted is Valeo, the cheap replacement I've bought is Mitsubishi.

[CitroJim]

That's a good price for a potentially very useful kit Matt

I've had a think about it and will get it ordered in the morning, I'll have to clear out and dedicate a second shelf to cheap Chinese special tool sets at this rate!



Whilst seeing if I could find any other options to consider, cheaper sources for the same, I stumbled across this interesting gizmo:

https://www.ebay.co.uk/itm/394480197285

Wondered if possible sphere removal tool?
(Have read on here about the actual sphere removal tools available on eBay, the DIY bend round a lamp post make your own and other proper ones) just saw it and wondered really.

It might Matt, the worry I have is the size and shape of it might not allow it to get over the sphere in some circumstances where they're tightly packed in and buried amongst other things and pipework... I can't comment on the C5 but this was a problem on the Xantia, even with the pukka Pleiades tool...

Can you test it on a sale and return basis if not good?

Knowing how delicate some small engine mag. flywheel finning can be, I'd be a little wary and cautious about using it for its interned purpose too...

[MattBLancs]

Held off ordering a tool kit, wanted to try and confirm what I've got at present. Plastic cover prised off and couple of terrible phone pictures:

I spy splines

Then macro mode and shove it roughly in the gap, by attempt 3 I got the but in question!

Splines outer, Torx on the alternator shaft.

Kit on order shortly

[MattBLancs]

Alternator, C5 = pulley removal kit ordered.


Back to the 406 Coupe and EW10J4 to EW10A swap preparations.

Oil filter housing (incorporating oil/coolant heat exchanger) on EW10A has two additional ports between it and block.
EW10J4S inlet manifold clashes with heat exchanger, so swap to EW10J4 oil filter housing instead, but need to deal with the redundant ports

EW10A block

EW10J4 oil filter housing= oh dear. But bolt holes line up

Gasket may or not have involved consumption of cider

Then this 4mm aluminium

Stitch drilled

Apply minor violence

Apply Dremel type tool, carbide but then 120 and 180 grit flap wheels

Ta da

Longer bolts and studs required, but another head scratching point dealt with

[CitroJim]

That's a top job Matt Loving the gasket material! Definitely a step up from my old staple - cornflake packets

[mickthemaverick]

Nicely sorted Matt, I love a proper bit of bod........er manipulating!!

[MattBLancs]

That's a top job Matt Loving the gasket material! Definitely a step up from my old staple - cornflake packets

Cornflake boxes ok, but strangely the grey cardboard they use is quite a bit weaker than the brown cardboard that beer, cider and oddly, Weetabix type cereals come in!

Gaskets formed by the "tap it out" technique - the EW10A doesn't have a flat gasket, instead a molded collection of O-rings as standard, so have to be a bit more inventive on this area.

[CitroJim]

I'll remember that about Weetabix boxes Matt

I have a little ball-pein hammer that's absolutely perfect for tapping out gaskets and it's done many over the years... It was always dad's go-to hammer for all the ones he made...

[MattBLancs]

Tapping out gaskets is one of those "strangely enjoyable" tasks. It's proven very handy on this job as allows me to tap a gasket from each half of a pair of mating faces - that way I can confirm compatibility of bolt positions as well as e.g. oil, coolant passages etc. Have done same for EW10J4S inlet manifold Vs EW10A head - there's some tweaking of the ports there as injector positions vary between the two it seems (would result in injector spraying against flat surface it appears!) So work to be done there and the couple of "gaskets" (which are the grey cardboard in this case:) ) will be my guide as to if I have done what's needed.

[MattBLancs]

And the EW10J4S inlet clears it, just!

Wider view

My potential interim solution was to get the standard inlet onto the EW10A, but ...

Interesting, the EW10J4 plastic inlet manifold does not clear it

[MattBLancs]

eBay bargain alternator arrived today, well wrapped - nearly a full copy of "classic car weekly" as the scrunched up padding - which now I've flattened out to go in the recycling I'm trying very hard not to read it!

Popped the plastic cover off gives a confusing sight:

The expected splines on clutch pulley, but only a smooth cylindrical hole in the alternator shaft!?! So Torx bit or similar a nonstarter for that. Hmm. Will wait for the kit to roll up, perhaps I can shock the pulley loose without restraint of the shaft.

Clutch pulley slips in one direction alternator generally seems fine. Though puzzled if this mounting position is supposed to be D shaped!

[MattBLancs]

eBay photo, zoomed in

Vs

Sat on my doormat photo, now

I'm wondering if parcel has been dropped on a hard floor...
Seemed pretty well wrapped but equally is a heavy lump.

[MattBLancs]