XANTIA HDi RUNNING ROUGH

[MattBLancs]

Cheers MattBLancs

I didn't think mine was too bad

Agree, doesn't look terrible really.

There's a lovely video of my garden instead of what I wanted my wife to video

Ah, video!

I forgot, here's a live action version of the heat gun making a good EGR flame thrower:

[moizeau]

I've used this
https://www.ebay.co.uk/itm/305477691439 ... +black&itm for the Zeph11 and will use it ro replace an O ring on the GPz11 cylinder head

[Rhothgar]

SO many TWISTED Firestarters in this group!

I cannot wait to do mine. I might take to doing it out front with a bit of Keith blaring out just for good measure!

[moizeau]

[myglaren]

[mickthemaverick]

I reckon this story needs a sequel!!

https://www.thenorthernecho.co.uk/news/ ... ds-damage/

[Huskyxantia]

Brilliant stuff and 100% dedication with out a doubt, I cant wait to read its all up and running this has been an interesting follow

[Skull]

Brilliant stuff and 100% dedication with out a doubt, I cant wait to read its all up and running this has been an interesting follow

Cheers, although it's taking me forever to get it back together .... 5 hours spent yesterday just getting the Intake Manifold on and torqued up, the main problem being access having to wiggle the exhaust/turbo around and insert all my extension bars together though the 'transmission tunnel' ....all bar No. 3's lower nut torqued to 17 Ib/ft (might be able to check that one, once the exhaust is back in place).

I actually wonder (in hindsight obviously) if the cylinder head would have gone on with the Intake Manifold already fitted (guess I'll never know now )

An old repair on a LHM return pipe was also re-done as it was clearly holding on to not a lot of pipe...

Skull's - Dodgy LHM+ return

Repaired again (third time) but it's getting a bit too short now ... each time you trim a bit of frayed pipe you have to drill the end to widen the internal diameter to match the pipe or it wont go on.

I could really do with some extra length ..... or a new octopuss but it seems more secure now

Skull's - Still a bit dodgy LHM+ return

The next job is probably the Coolant Outlet

Then the Exhaust and Turbo back on (I think I'm still missing a couple of nuts that were dropped and haven't re-appeared yet ....)

Quick question if anyone knows ..... There doesn't appear to be an EGR to Intake Manifold gasket fitted or in the kit, will a bit of the gasket sealant do the job

Whilst shoving the turbo around yesterday I got a look at the tiny impellor .... looks and feels in good condition ....but much smaller than I was expecting ...

Skull's - Tiny Turbo

[Rhothgar]

I actually wonder (in hindsight obviously) if the cylinder head would have gone on with the Intake Manifold already fitted (guess I'll never know now )

Where's the harm in taking it off again for a bit of practice...

An old repair on a LHM return pipe was also re-done as it was clearly holding on to not a lot of pipe...



Repaired again (third time) but it's getting a bit too short now ... each time you trim a bit of frayed pipe you have to drill the end to widen the internal diameter to match the pipe or it wont go on.

I could really do with some extra length ..... or a new octopuss but it seems more secure now



The next job is probably the Coolant Outlet

Then the Exhaust and Turbo back on (I think I'm still missing a couple of nuts that were dropped and haven't re-appeared yet ....)

Quick question if anyone knows ..... There doesn't appear to be an EGR to Intake Manifold gasket fitted or in the kit, will a bit of the gasket sealant do the job

Whilst shoving the turbo around yesterday I got a look at the tiny impellor .... looks and feels in good condition ....but much smaller than I was expecting ...

Brilliant! Keep going. Inspirational. I know it is no fun taking the inlet manifold off which is why I have had a gasket sitting in the boot for years waiting for me to take it off and clean it.

As far EGR to intake manifold gasket, that's a good question. I read it wrong initially and was going to say it's a metallised gasket but that is to the exhaust manifold. There are a couple of EGR configurations on the HDi DW10. I think mine is a push it almost with a concertina pipe?

Tiny turbos are gooooood! They spin in fast at low revs and don't lag. If you're up for a laugh add a large one too for the best of both worlds. The turbo on my Saab T16S is huge. 3-4" manifold from memory which is why it doesn't kick in until 3000 rpm but when it does, you don't want to be on the autobahn at 85mph in damp conditions as the wheels will spin...

[mickthemaverick]

EGR to inlet manifold on my old C5 was an exhaust paste job. Worked for me!!

[Huskyxantia]

That's a nice clean turbo no signs of impeller wobble either

[CitroJim]

Looking very good Gary

[Skull]

Exhaust manifold is back on and mostly torqued up (15 Ibf/ft) although No. 3 lower stud must have threaded slightly as the stud wouldn't fully tighten and although the nut has tightened up more than I thought it would, I haven't risked torquing it up fully.

Some of my struggle ....



This was over 3 days (about 15 hours fathing around tightening and undoing several times trying to get all the studs in correctly) eventually removing the offside engine mount to allow the last stud No.3 upper in the above video to be fitted, followed by the Coolant Outlet being fitted - photo shows bleed vent on top of thermostat housing (5mm Allen Key)

Skull's - Coolant Outlet re-fitted

One of the Exhaust nuts dropped on removal still hasn't been found (alternative fitted to No.4 lower stud) and my only worry is that it's fallen in the exhaust manifold ready to chew the turbo (worst case).

Additional delays trying to find the rubber breather pipe that joins the Camshaft Cover to the Intake Manifold .... the search continues .....

Also I can't find a torque setting for the Turbo oil supply banjo type fitting ....

[MattBLancs]

One of the Exhaust nuts dropped on removal still hasn't been found (alternative fitted to No.4 lower stud) and my only worry is that it's fallen in the exhaust manifold ready to chew the turbo (worst case).

Oh that worry would eat away at my mind!

Trying to think if removing the EGR valve would give means of introducing a borescope for a quick check?

Also I can't find a torque setting for the Turbo oil supply banjo type fitting ....

Hang on will have a quick dig

[MattBLancs]

Found it, Peugeot 406 Haynes manual (#3982) Diesel engine in car repair procedures.

From Haynes

Turbocharger lubrication pipe
Engine side 30 Nm, 22 lbf.ft
Turbocharger side 20 Nm, 15 lbf.ft