Gareth's S1 Activa Progress Report

Deanxm · Unread post by **Deanxm** » 23 Nov 2010, 21:52

i like them because the site is laid out well, its one of those places where you find things you dont really need

D

XantiaMan · Unread post by **XantiaMan** » 30 Nov 2010, 16:02

Right, sorry for the delay in updates, i've not touched it for a week!

I managed to brave the cold wind and snow flurries and made the following progress.

Clean the manifold up, used 80 grit as it was quite corroded. The gasket bits into this like a fire-ring type seal on the cast iron, opposite side is metal composite on the alloy head. The head was cleaned with purple scotch, it wasnt too bad and felt ok, had to see without a mirror here.

Once cleaned up, i refitted the manifold over the head studs, and onto the turbo. Fitted a few nuts loosely. The new nuts i got supplied with are hard copper, about 3/4 in in length, so more of the nut contacts the stud and should provide greater torque than the originals. However the originals have to be used on the two lowest nuts below the turbo, there is not enough space.

Thew new fire ring for the turbo to manifold face is fiddly. It fits in place ok, i used a knife to hold it whilst lifting the turbo up, slide the knife out and then nipped the bolts up. I did the bottom first, the studs came out on the top when they were removed, refitted the same and torque FT.

You will need a nice slim 10mm 12 point spanner for the lower most nuts under the turbo.

So now the manifold is in its correct place, so is the turbo.

I took the opportunity to modify the heatshield, it should not make it any less effective, and meant i could refit it with ease once everything bolted in. Basically the rear snail part had around 1 inch cut off, and the sides which curve around the turbine housing were trimmed too, job done!

So really its a case of refitting all the little bits. Once the remaining nuts are tightened, the turbo brace will be refitted, the coolant feed pipe union too. Then a change of sequence, the downpipe will be refitted, reason being you need good access from the top to get the bolts and spring on without getting totally pissed off with them!

Ideally, i need to find a spare downpipe/cat to borrow, i am going to have a copy made minus the cat, in 60mm pipe. Shouldnt cost more than £50. I can then refit the cat for MOT time.

Engine mounts then, bolt the headshield in place, refit the oil feed, make a new inlet pipe with the new pipercross filter, top up coolant etc.

Although turbo has only been disconnected not removed, it makes sense to prime it with oil before the feed is fitted, turning the compressor wheel making sure its well lubed up before starting.

Not long now, and i can enjoy the nice quiet purr of the CT engine (till i fit the bigger exhaust

)

Unread post by **CitroJim** » 30 Nov 2010, 19:08

Excellent work Gareth...

Somewhere I heard to hold the turbo fire ring in place with a dab of superglue... Seems like it may work...

Well, as you might have gathered, I have this job on Xac's in the New Year. I'm mighty grateful for all the solid-gold information you've provided. It's going to make the job a breeze...

By way of a thank you, I have a spare cat you're welcome to borrow as a pattern. You can have either Ollie or Fluffball or even both. All they do nowadays is just spend their lives asleep by radiators...

Sorry, not that sort of cat...

What will you do with the lambda sensor on a de-cat with regard to positioning it?

XantiaMan · Unread post by **XantiaMan** » 30 Nov 2010, 19:21

Hi Jim, it was me that mentioned the superglue, however in the event i tried to fiddly it in instead and seemed to work, the turbo nipped up ok anyway, if the ring had fallen out of place then it wouldn't of tightened up square. The fire ring is designed to crush a little as you know, so its essential it is replaced every time the turbo is removed.

The downpipe can have a lambda boss welded into the OE position.

If you have spare i can borrow that would be great. No fluffy ones, the ones we have here are a PITA..

Deanxm · Unread post by **Deanxm** » 30 Nov 2010, 19:38

Good Job Gareth, wont be long now then untill its back in action, i just welded a Lambda boss onto my decat pipe and it works a treat, actualy its better than oe because i welded mine on pointing out to the side where you can reach it, not on top

D

XantiaMan · Unread post by **XantiaMan** » 06 Dec 2010, 15:38

I picked up my new shiny nuts this morning

and managed to get them fitted.

I took a few pictures. The first shows the old and new nut side by side.

These new nuts fit fine on all except the lower two manifold bolts where the turbo makes access difficult, as it is such a fiddle i kept two originals in this spot and replaced all the others with this new type. They have a wider seat, the length is longer and uses all the stud length, so should exert more torque as a result and maintain it for longer.

I am still of the opinion that the studs are too small and larger ones would of worked better, but this should do the job.

Next picture, shows the manifold and turbo in situ. Space is non-existant until the turbo inlet and outlet are removed, so this picture doesnt really do it justice, the engine was sitting around 1 inch further forward than normal in this picture.

Note the heat shield in place at this stage to see that it refitted fine.

Next picture with shield removed, shows the new nuts in place. Nipped up first with a 13mm spanner and then finished off with a 13mm six sided 1/4 in socket, all gradually torqued up, i've gone FT on them because of their reputation for coming undone and thats how i did my old Activa.

I have test fitted the inlet and outlet pipes for alignment, they will be removed and the downpipe refitted first from the top, then refit the pipes, refit the top engine engine steady and then it leaves the turbo support bracket to be refitted, a clip on the actuator, the bottom engine steady and a few bits and bobs.

Really not much else to do but its soo cold at the moment, its a good job i can take my time although i am itching to hear it restarted nice and quiet!

XantiaMan · Unread post by **XantiaMan** » 07 Dec 2010, 18:28

BTTT, in case anyone missed it!

Unread post by **CitroJim** » 08 Dec 2010, 16:42

XantiaMan wrote:BTTT, in case anyone missed it!

No, I didn't miss it

Just more encouragement for when Xac and I come to do the job.

I ordered the gaskets yesterday. Was tempted with the nuts. They certainly do look a lot more workmanlike...

XantiaMan · Unread post by **XantiaMan** » 08 Dec 2010, 19:16

Get the nuts, ok a bit more expense but if it helps prevent the blowing again its worth it.

XantiaMan · Unread post by **XantiaMan** » 12 Dec 2010, 13:14

We are nearing very close to completion on this.

The turbo support brackets are back on, the coolant support pipe bolt attached. Oil feed nipped up, and the bottom engine steady.

I have a friend who has obtained the exhaust downpipe fitting kit and will assist me with refitting the downpipe on Tuesday, its much easier with two people!

Then all i need to is top up the coolant, refit the inlet pipes and off it goes.

However in its time its been stood up, i now have a weep from the front ram area, this could get interesting.

Unread post by **CitroJim** » 13 Dec 2010, 17:24

XantiaMan wrote: However in its time its been stood up, i now have a weep from the front ram area, this could get interesting.

No worries there Gareth

We have a solution for that

XantiaMan · Unread post by **XantiaMan** » 13 Dec 2010, 19:36

I checked this morning and it hasnt dripped any more since i wiped it, its defintly the return seal, not the pipe that comes out, the part that forms the seal around the body. My old Activa had this same weep when temperatures were below freezing for more than a few days, if it was used everyday it may prevent it but i know from experience that once it warms up and the car is used, it stops, just a weak point with a used ram and something to keep an eye on.

I picked up the new fitting kit this morning for £6, my friend will be over tomorrow to assist the refitting, if you recall Jim it was significantly easier with two people!

It should all be up and running, fed up with seeing it on axle stands and immobile! It will be parked on the grass once it moves again as i doubt i will drive it that often yet, but with another cold snap its not very encouraging to get out there and have frostbite on your fingers after 5 minutes.

Unread post by **CitroJim** » 13 Dec 2010, 19:42

XantiaMan wrote: I picked up the new fitting kit this morning for £6, my friend will be over tomorrow to assist the refitting, if you recall Jim it was significantly easier with two people!

Absolutely, it can be done single-handed but in common with a lot of Xantia jobs, it's so much easier (and more sociable) with two of you

Bet you can't wait to drive it again. I don't drive mine too often but when I do, I really do enjoy it and it reminds me why I have an Activa...

Sl4yer · Unread post by **Sl4yer** » 13 Dec 2010, 20:21

XantiaMan wrote:My old Activa had this same weep when temperatures were below freezing for more than a few days, if it was used everyday it may prevent it but i know from experience that once it warms up and the car is used, it stops, just a weak point with a used ram and something to keep an eye on.

Yep, my rear ram is leaking again now, just as it did during the cold spell last winter. Not a drop through spring summer or autumn though. Luckily, I got it MOTd at the start of November, just before the cold hit.

James

XantiaMan · Unread post by **XantiaMan** » 14 Dec 2010, 16:17

Guess what, the rear ram had a weep too! Not going to worry about it for now.

Anyway, good news is that its now up and running again!

I still need to finish a couple of bits off, mainly the induction, and i'm trying to source a manual boost controller as mine has disppeared.

But for now, its nice to hear an unticky manifold gasket, a shame the centre pipe/downpipe is blowing to spoil the fun, thats the next job and i have a chap i know who may be able to put something together for me very cheaply.

I've only run it down the road, its is very sprightly regardless of the standard boost, far better than i remember my S2 being when it was stock.

Its not had a clean yet, so pictures are limited but you get the general idea.

I will be removing the dump valve, the impellor flutter noise is ample for now and the Pipercross filter is not too noisy. I will be making a shroud for it for heat from the engine and radiator do not get reflected into it.

Refitting that downpipe was a bugger, even with two people access is a proper PITA!

Looking forward to driving it now!

Just uploaded a quick video on youtube, you can see and hear it there..