Xantia-Crankshaft pulley bolt 1 Newcastle Falcon 0

citroenxm · Post by **citroenxm** » 05 Jul 2010, 21:32

Inlet manifold has to come off, not too bad, the awkward one is the centre 13mm bolt that has the turbo feed pipe in the way to get a deep socket in there...

You can take the head off with turbo attached but you then need to get back under neath to remove the turbo feed and drain pipes from the block.. so again its best to remove the 6 studs that hold the exhaust manifold/turbo to the head... it can be left sitting on the exhaust..

you ALSO need to remove the stud that goes through the top engine mount into the head, its the one that has the 10mm nut holding the belt cover on, forward of the cam shaft sprocket, its a 13mm head bolt then behind it 16mm thread to pull it out... IIRC this is NOT mentioned in the book..

You also need to remve the 13mm nut that goes through the upper part of the belt tensioner.. its directly nder the cam sprocket... theres no need to remove the tensioner..

YOu'll also need to remove the Engine hoist point bracket from the gearbox end of the head, as it has a sump that sits into the head to stop it comming away..

Regards
Paul

jgra1 · Post by **jgra1** » 05 Jul 2010, 23:00

my xantia blog has a few pics of the TD out.. may help to show some of what Paul is mentioning

john

NewcastleFalcon · Post by **NewcastleFalcon** » 08 Jul 2010, 10:11

thanks for the replies

Maybe I need to start a new thread

"Inlet manifold allen bolts 1 Newcastle Falcon 0"

Access is hopeless. I have used the appropriate Allen Key and managed to get the easiest access one out but have only succeeded in damaging the head on each of the remaining allen bolts.

As said in previous replies the inlet manifold has to come off to get decent access to the rear bank of cylinder head bolts. There is irritatingly not quite enough room to get the torx bit and the associated paraphanalia above it to remove the bolts.

One solution is to hacksaw off the inlet manifold, get the head off and dismantle the inlet and exhaust manifolds when it is off. Bit drastic but I cant think of an easier solution at the moment.

thanks neil

citroenxm · Post by **citroenxm** » 08 Jul 2010, 10:14

I got a good few inlet manifolds if you want to do that!!

Can easyilly send you one!

Paul

jgra1 · Post by **jgra1** » 08 Jul 2010, 10:15

Neil. try removing upper RH engine mount (with jack underneath) use a scissor type jack between bulkhead and engine and force engine forwards a bit (at the RH end) should now get better access behind there..
watch the rad and hoses etc.. but your only 'twisting' the motor a few inches

Paul, do the manifolds really need to come off? if they are being a pain.. I cant see why?

MikeT · Post by **MikeT** » 08 Jul 2010, 11:58

citroenxm wrote:I got a good few inlet manifolds if you want to do that!!

Can easyilly send you one!

Paul

Hi Paul, have you got a 1.9TD manifold WITHOUT the EGR revision?

citroenxm · Post by **citroenxm** » 08 Jul 2010, 12:40

Yes John they do HAVE to... the Xantia has a Curved manifold that comes over the top and obscures the rear set of bolts..

Mike, Im sure all manifolds are NON EGR ones, Ill have a look at the weekend.. send me a reminder friday evening!!

Paul

jgra1 · Post by **jgra1** » 08 Jul 2010, 12:45

ahh yes I remeber now...

NewcastleFalcon · Post by **NewcastleFalcon** » 11 Jul 2010, 19:47

I am back in the game just a couple of the inlet manifold bolts to come off now.

Yes I have made another schoolboy error. While the allen key I selected after routing around in the bottom of the toolbox appeared to fit and indeed did remove the easiest access bolt I suspect it was an allen key of old imperial dimensions.

After discovering a newer shinier set I assume to be of metric dimensions, I have now succeded with most of the bolts. The hacksaw is not required as yet but thanks for the offers of access to inlet manifolds if the remaining bolts aren't so co-operative.

Allen keys aren't stamped with the size on them are they? My inadequate method of trial and error and selecting one that fits came unstuck this time, and together with a disorganised set of tools I have created a fair amount of unnecessary hassle for myself.

Is the proper size for the allen key 5mm for the inlet manifold bolts?

Thanks

Neil

citroenxm · Post by **citroenxm** » 11 Jul 2010, 20:21

The allen head bolts are 6mm HEAD, not 5!

Good quality keys are marked with their sizes...

Glad to hear your winning!

Paul

MikeT · Post by **MikeT** » 12 Jul 2010, 11:00

Post by **CitroJim** » 12 Jul 2010, 12:06

MikeT wrote:

Spam removed Mike...

MikeT · Post by **MikeT** » 12 Jul 2010, 12:50

Good man! I knew it wouldn't last long.

NewcastleFalcon · Post by **NewcastleFalcon** » 12 Jul 2010, 19:48

Inlet manifold is off. That 13mm bolt in the centre is in an awkward position. I didnt have a deep 13mm socket and it seemed there just wasn't a position where you could get the bulk of the ratchet, or t-bar in to undo it. Got a 13mm ring spanner on it but getting sufficient leverage to undo it was proving difficult. In the end I used a hex 13mm socket, with a 13mm square ended drain plug key in the end, and a 17mm spanner acting on the main body of the drain plug key, and hit the ring end of the spanner with a hammer. Not recommended but it worked.

May have spotted an error in Haynes! 4B 15.6 says:

"loosen but do not remove the central hexagon manifold securing bolt-the manifold is slotted"

Unless I have missed something, The manifold on my 1.9TD doesnt appear to be slotted, and has a hole where the central securing bolt goes through.

Almost ready to undo the cylinder head bolts. I have removed one 13mm through bolt to the cylinder head from the engine mounting. Is that all that is required on that side to get the head off? Camshaft and camshaft spocket all completely off.

Looking at the exhaust manifold nuts/studs I feel that I would be really lucky if none sheared off, so I would like to remove the head with the exhaust manifold untouched. I have disconnected the exhaust downpipe.
Which are the 2 bits on the turbo which need disconnecting to free the head whith the turbo and exhaust manifolds still attatched. The oil feed pipe union is one probably. Apologies if this has already been answered I will look up the thread after this post. If possible I would like to do the disconnections at the turbo rather than crawling under the car.

thanks Neil

Post by **CitroJim** » 12 Jul 2010, 20:21

Well done Neil, getting that manifold off is a tricky old job and you showed great ingenuity in getting at the centre bolt

Haynes are wrong for late manifolds but earlier ones were slotted. There were two reasons, firstly that bolt is a devil to get back in with a manifold dangling and secondly it acts as a sort of dowel when there is a slot. less perhaps a dowel but more of a location and convenient peg to rest the manifold on. Still, it's only light alloy so not that weighty...

You'll be pleasantly surprised with the exhaust manifold studs. They rarely put up a fight. If you remove the stud complete you can leave the manifold and turbo in place and that makes sense - the head with manifold and turbo attached is seriously heavy. If a stud stays in, use the old "double nut" trick to get it out - that's two nuts on the stud, one tightened against the other and the lower one used to undo the stud.

It's coming along a treat. keep up the good work