Active Engine Removal (And refitting)

XantiaMan · Unread post by **XantiaMan** » 21 Oct 2009, 21:25

As i was saying to you on the phone, i notice any noise, noises that no-one else can hear! My driveway doesnt help, i think i should spend less time with the bonnet up and just get on with driving

Work will continue this weekend as i am now away for a few days. It needs a few hose clips nipping up (including one on the throttle body), i may invest in that special tool you got from Halfords as my Transit uses the same clips in many places.

Will 1.2 litres of oil in the gearbox be ok until i can check the level properly? A friend of mine works at a garage and it can be checked on a ramp.

A few cable ties will be needed to make sure the gear linkage is clear of obstructions. The ECU needs a tidy up as the wiring mod makes it difficult to get back in its box properly now its been disturbed. Wheel arch liner needs securing and thats pretty much it, done!

XantiaMan · Unread post by **XantiaMan** » 25 Oct 2009, 10:35

Solved the ticking problem

And it was an odd one

Started it this morning as i had been away a few days, and off the noise went. I had a closer listen, and was still convinced it was coming from the bellhousing area, but also the front of the engine near the starter motor.

I luckily, took off the good one from the spare engine, and gave it a twist with my fingers. It made a similar sort of noise

So i took a look, and found one bolt missing. Not enough for the starter to fall off though, as it was well located with the other two. Undeterred, i took the starter off completely, with such theories going through my head like a sticky solenoid, or possibly it got damaged when refitting the gearbox.

Whilst it was in bits again and replacing the missing bolt, i cable tied a few bits in the gear selector area, and to make it a it tidier.

I also found one clip on the gear linkage was the wrong way round as was finding its way off, the main issue is the cable would not be solidly located and of course, i could lose a few gears!

This was easy enough and the gear selection is like new now with the replacement linkage assembly.

The moment of truth, i refitted the battery and started it up. No noise

Happy is an understatement as i was fearing the worst, but set about it in a logical manner and for once, it paid off. 8)

Air filter and pipes need to go back on, and a water hose needs a jubilee as i cannot refit the original, its now stretched and wont go back into place.

Unread post by **CitroJim** » 25 Oct 2009, 19:23

I'm really pleased that mystery is now solved Gareth

Indeed a strange one. Sounds like the gear was rattling on the shaft. Still, not to worry, It's solved and that's all that matters...

Any news yet on how the new turbo is performing?

XantiaMan · Unread post by **XantiaMan** » 26 Oct 2009, 12:12

With all the little odds and ends sorted i took it for a drive this morning.

After a careful warm up i gave it some beans. Overall, the power delivery is much the same, pulling well from 1500rpm. The actuator could do with a little tweak for more pre-load, something i will do on the ramp.

It does seem to pull nicer up to around 6k and doesnt seem as breathless. Its running around 11.5psi, so once the boost is set up correctly at 12.5, it should be quite interesting.

One downside is the extra noise. It really does whoosh alot more, but as the original was as silent as a mouse, it doesnt mean there is anything wrong, and i quite like it!

Strangely, after leaving it for an hour the stop light went straight out on restarting, something it didnt do before

All other behaviour is as it should be, and i'm very happy with the clutch and gear selection, and its soo quiet now!

The turbo mod has done what i wanted, giving a little bit more poke but not changed the characteristics or originality. To make a lot more power, a bigger turbine side would be needed and that would take away the smoothness and response of the original set up. For me, its pointless doing that and making it more unrefined, i will always fight a battle with the weight of the car.

Now, once finances are sorted, i can get the decat pipe which will free it up even more. That will complete the mods, as i like the car as it is.

This has been quite a stressful exercise and by far the most nerve racking job i've done on a car. Years ago, i used to take engines out and rebuild them without a second thought, but the Activa is a complicated beast that needs looking after.

Unread post by **CitroJim** » 26 Oct 2009, 12:33

Delighted all is good Gareth

That Stop Light behaviour is a sure sign of a very sound hydraulic system with no leaks

You should be proud of yourself there, you've done a great job but I do know what you mean about nerve-wracking..

I've come to the conclusion that the Activa is the hardest engine of the lot to remove/replace, V6 included...

XantiaMan · Unread post by **XantiaMan** » 26 Oct 2009, 15:30

I found a big split in the air inlet pipe between the air filter and the main pipe for the turbo, so this may be a cause of the noise

Strange that it seems to of happened at the same time as the engine out, but, maybe disturbing it on this occasion was enough to show the problem up.

I remember KP mentioned this pipe had split on his S1, which sounded exactly the same in my ownership. Sadly, masking tape isnt doing a very good job, not surprising when you imagine the volume of air being sucked in.

New pipe on order, £30!! Be here Wednesday

Without your help Jim, and others on this forum, i would not of attempted it any time soon. The car is a credit to you and FCF as to what can be achieved, and as ever its a pleasure to drive.

XantiaMan · Unread post by **XantiaMan** » 26 Oct 2009, 15:41

superloopy1 wrote:Well done Gareth ... a good read

I'll know who to come too when my clutch needs doing

You would have to catch me in a very good mood! (and the missus)

I'm still tempted by my old Xantia, but we have a couple of issues to ride through first. Don't scrap her yet!

KP · Unread post by KP » 26 Oct 2009, 19:21

The pipe is certainly a very weak point, i dont think it helps if its never been taken off and cleaned as i can bet that dirt collects there and grinds away at the joints. Mine has now split in two places and with current issues on the car can't get far enough to order that pipe as yet as got two other things on back order with citroen still

Be wary of the one that comes, as if its old stock then give it a good clean and silicone clean up to ensure it lasts long enough. I think it would be better at some point to get a batch of 10 made up in silicone to replace them.

Also the bellows stretch quite a bit if you watch it as you pull the clutch up or rev the engine...

XantiaMan · Unread post by **XantiaMan** » 26 Oct 2009, 20:03

KP wrote:
Also the bellows stretch quite a bit if you watch it as you pull the clutch up or rev the engine...

Yes i noticed this. Its noiser when you are harsher with it, and have more engine movement. Heat appears to of hardened the old one, and it is ten years old. The engine bay will be getting a special clean soon which will include some treatment for the hoses.