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Old 30-07-2016   #31
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Re: John Dragon Man's Citroen BX Diesel Estate

EGR's have one good point and that is they really reduce nox gasses (which is not something that has to meet requirements on a UK mot test). they do slightly help to heat the diesel engine when cold starting too.

the EGR on most diesels are normally service items requiring cleaning at given intervals but they always get overlooked.

this one i dont think has ever been done looking at it. its pretty chock-a-blocked in there.

new set of glow plugs bought for it too.. ill change them over to help with starting
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Old 11-09-2016   #32
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Re: John Dragon Man's Citroen BX Diesel Estate

ahh so i have done a bit more work on the BX.

so the engine now has had the oil pump swapped over (for the slightly lower miles one). i am not sure if i should have, but i made a gasket for the oil pump chain cover too.








its a bit mucky inside with some oily buildup, i cleaned it out the best i could but when i have built it all up and running i will run some cheap oil through it with some engine flush.



anyway. the replacement BX cam shaft has been installed, the 4 shaft oil seals have been renewed (crank and cam), the oil sump from the original engine has been swapped over to the replacement engine, the cam cover oil seal and sump oil seals have been renewed, the water pump has been changed, new Bosch glow plugs installed, and the engine has had a bit of a quick lick of paint just to see how it's going to look.. and boy does it look nice!





i will be painting the whole engine red plus the gearbox, pumps and alternator. agricultural/marine style.



i then started to remove the drivers side wing, the wing skins (both sides) themselves are in fantastic condition. ok the paint has gone a little thin but dent and rust wise, there's none!
under the skins on the shell its another story. though not bad (given the age of the car) we do have a little rust. i knocked out as much as i could and even got the jet wash in there to clean it up a little more.





i also took all of the brakes apart too as i am replacing all of the brakes.. the fluid in the brake pipes.. did not look like LHM :/

i also found this nice pipe with a few good splits in it, the one on the other side was completely split with a section of the 2 pipes missing!




now for the other side to be removed.. and.... oh my! it looks good in here!


just a little bit here..

... and a bit more..


but as it goes.. better than the other side. nothing i cant fix!

aaand of course.. here is another video log (4th one) for you guys to watch:

https://www.youtube.com/channel/UC4N...eX_hCgTEygva7A


till next time!
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Old 15-09-2016   #33
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Re: John Dragon Man's Citroen BX Diesel Estate

righty ho!

so today i have been pulling most of the returns out of the engine bay, they are a pretty sorry state with multiple splits laddering all the way up the pipes. needless to say i will be replacing the lot with nylon "air tubing" pipe. i have had great success with this stuff before using it to transfer oil on the waste oil burners i have built for my workshop (even used it as petrol fuel line on my old panda!).

so i have uncovered "The Octopus". i am not going to say how i feel about this thing other than wanting to nominate the designer for a great design award.

with most things broken i decided to take it apart.. as i will make my own haha.

so here we have it as i took it off the car.



splits n all


so i found out what all of the pipes do and what pipe connects to what... and i found out that the octopus is in 3 parts.



and where i have cut it, there are no internal pipes



as seen:






so that said, it looks like this thing would be quite easy to make out of simple T pieces and say 6mm push fit tubing (which is rated at a 10 bar connection! 16 bar for the other kind!)

so to be a little colourful i am going to buy a 30m reel of lime green 6mm air line, a load of push fit connectors and renew all of the return pipes. just wish you could do the same for the high pressure stuff.. sigh.

i will of course have to use some rubber (fuel line) pipe for connecting to metal returns, but that is stuff i can keep an eye on more easy than the whole lot!

while i was under the car i also changed the drivers side steering rack boot/gator. nice and easy on that side! the pass side looks a little more hard.. i think i have to unbolt the hydraulic actuator arm from the rack to fit the boot over it.. i will have a go at it tomorrow!
before i put it all back together, i will replace the ball joint dust covers and give them a little more grease too. i am shocked that none have any play in them! then again, all the dust covers are in pretty good condition!
even the anti roll bar bushes do not seem to have any play or even ware in them! makes a nice change to be fair..

all of these pipes though.. its giving me a little bit of bewilderment.. i just hope i can figure out where they all go!
i did see a nice picture of the top of an LHM tank on the BX owners forum and it was labelled as to where all of the pipes came from. if i follow that, i should be OK. the best bit about using this air line is you can just cut a pipe anywhere and use a connector on it. really, if you have never used this stuff before, i recommend it! (i have even used it on model steam engines!)

i will report back tomorrow on the success/failure of fitting the pass side steering rack boot/gator.
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Old 15-09-2016   #34
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Re: John Dragon Man's Citroen BX Diesel Estate

oh and here, i emailed these guys to ask them if they could make me some pipes up for the brakes and suspension.

here is the price list of all the pipes (for a Citroen BX Diesel Estate with ABS) from Pleiades:

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Old 17-09-2016   #35
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Re: John Dragon Man's Citroen BX Diesel Estate

looks like the gators i have are for a manual steering rack.. the PAS rack gators are much more hard to find!... well way more expensive to buy anyway. whatever.. needs must.

it seems that the drivers side gator is the same on both PAS and none PAS. the other one though.. ahh well.
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Old 22-09-2016   #36
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Re: John Dragon Man's Citroen BX Diesel Estate

My brother had a 'H' reg Citroen BX 16v for a number of years. Thing was a beast, the sound system was worth more than the car! Pulls well for an old timer.
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Old 24-09-2016   #37
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Re: John Dragon Man's Citroen BX Diesel Estate

hmm guess i forgot to reply back to this.. anyway.. one week later.. ahem..

the gator has not been done yet.. heh i have some universal ones that i have used on the drivers side and was going to use on the pass side. however i find that they do not "fold" small enough. the gator gets sort of crushed when on full lock to the point where it actually folds in on its self!

it looks like it would happen on the hard side to replace them on too. so i went out and bought from ebay, a pretty expensive gator.. and found that it will do the same thing as the cheap universal one. sigh

i have to get this black rubber gator OVER that sticking out thing (that the hydraulic actuator bolts to) so it covers up that shiny metal part where the grease is! thats some stretching!


i also painted the rest of the engine.. making sure i got the paint everywhere on all of the pulleys (not intentional). i am not too fussed about that as it will be under the plastic covers. i will scrape off the paint for the manifold gaskets.



i managed to get hold of a none ECU controlled bosh fuel pump! ... and painted that red too.. along with the bracket



the gearbox has also been painted red. this enamel paint has got to be the best paint i have ever used!

i also managed to rip out the cars original alarm (i assume a dealership fitted alarm). i have no remote fobs for this so it is pretty useless. it was however all tied into the original engines fuel pump so i assume it had a built in immobiliser.
i will be fitting a different alarm in its place, something along the lines of a Toad ai-606 alarm. i quite like them, all of my other cars have them fitted (they are easy to pull out of scrap cars) it wont be something i'd do till i got the car parked on the drive at home.
the thing was also wired into the front fog lights.. maybe as night time illumination lighting? sadly theres not much info on this alarm so i dont know!

the tow bar wiring is a bit crazy as its involved with the alternator AND blue glow plug relay box thing.. ill have to dig around that a bit to see how its wired in.. my guess is its some kind of system where it only gives power to the rear socket ONLY when the engine is running.. the tow bar electronics look dealership fitted. (different to the alarm). also wow so many wires behind the glove box! cant wait till i get to have a play in all that lot (i am one of the very few people that love auto electronics and wiring its nice to have a car that has more than 20 wires for once!)



not started running the pipes yet.. and not yet bought the new replacement high pressure stuff.

i need to replace the heater tap which i have had come through the post.. and while i am at it i will install the brand new heater matrix.

after the replacement high pressure pipes, the only thing i need to buy next would be a VNT turbo and that should be all of the big spending done!

i know i need pretty much ALL of the rubber pipes that the XUD engine uses. that includes oil pipes, breathers and some coolant pipes. i dono where i am going to find them.. sadly every pipe i took off split.. on both engines!

well it will be next Thursday till i get a chance to do any more playing with the car. (i can only get to work on it every Thursday and Friday

Last edited by Dragon Man; 24-09-2016 at 03:05.
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Old 24-09-2016   #38
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Re: John Dragon Man's Citroen BX Diesel Estate

Quote Originally Posted by Dragon Man View Post
i also painted the rest of the engine.. making sure i got the paint everywhere on all of the pulleys (not intentional). i am not too fussed about that as it will be under the plastic covers.
I think you'll need to get the paint off the pulleys, as it will affect the way the cambelt operates. A cambelt will naturally run on the centre of the pulleys, but the paint may change that. May be a bit of a risk.

Of course, the belt may just take the paint off quickly, more easily than you scraping it, but it may require a belt change sooner rather than later.
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Old 25-09-2016   #39
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Re: John Dragon Man's Citroen BX Diesel Estate

wire brush on a grinder, or at a push on dremel, will have the pulley cleaned up in no time I'd not leave it myself either, better safe than sorry - we seen what happened to the last camshaft!!
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Old 25-09-2016   #40
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Re: John Dragon Man's Citroen BX Diesel Estate

Careful with a wire brush. Pulley dimensions are important, so no surface damage wanted. Careful use of paint stripper might be possible, or the softest abrasive brush you can find. If such a thing exists. Do Dremel do harsh nylon brushes or similar? Or ruin an electric toothbrush on it.
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Old 26-09-2016   #41
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Re: John Dragon Man's Citroen BX Diesel Estate

they do steel and brass wire wheels for the dremel, brass one would be fine, i use them on countless bits of engines and they don't even scratch brass being so much softer than steel
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Old 29-09-2016   #42
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Re: John Dragon Man's Citroen BX Diesel Estate

i will use thinners to clean them up.. at least the stuff evaporates and does not leave much behind.. then i could use meths to clean whats left.

anyway, work done today:

managed to get the gator on the steering rack.. wow what a job that was! i was having to stand where the engine was so i could get enough pressure on it to push it over the mount for the hydraulic power steering actuator. damn! i wonder why they did not just make it a bolt.. really interestingly designed that one.





i am concerned as to how much the gator is crushed when you turn to full lock.. this cant be right surely? the gator is on the maximum amount of stretch when the steering is turned the other way. both of the gators i have are like this. one was a cheap one, the other is one i bought (for a damn lot of money) that sad it would fit the BX with power steering.... i cant see this lasting very long...



so remember that rust issue i had? well i managed to get a welder i can leave at work. (though its not been used for many years and all rusted up).
i decided to get the cutting disc on it and take off the first skin to see how it was on the underside.



hmm yeah it was to be expected i guess. its not much of a problem..

cut out the worst..


make a plate the same size (or close enough) as the hole.. (even managed to find some replacement steel the same thickness!)



and after taking ages to set up the new welder (spitting and not welding good) i eventually got it to weld nice and welded a new bit in..



rather than spot welds i am going to plug weld it. (as i do not have a spot welder)

after a bit of a clean up it should be OK... some paint then under seal it should not rot out again.. ever! i just need to do the same with the under side (bit under the washer bottle).

lets see what tomorrow brings!
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Old 30-09-2016   #43
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Re: John Dragon Man's Citroen BX Diesel Estate

Ok so here is tomorrow, and what do we have...

well i started welding the outer skin on and the gas ran out on the welder to be fair it was a Co2 fire extinguisher we had weighed in at the scrap yard i work at, but it did at least one good bit of welding. this is all i managed to do.. then after i welded it on i realised that i have not drilled any holes in it for the plug welds #-o .



well we have no more at work but i will bring one in next week as i have a few at home, so i can finish off this bit of welding here.

after that i just spend most of the day rebuilding a bit of the engine back up, i also spend a while cleaning up the cam belt cover plastic guards and gave the gearbox a second coat of paint.





i really need to paint them injector pipes too,, sadly i have ran out of paint! :shock:












oh and i finally got enough cash together to order the new pipes from Pleiades Car Services (url linked to there facebook page). the total cost combined with VAT and postage came to 243.96. they do come ready to fit to the car though with flares and all new seals

i guess its time to start looking for the VNT turbo... i am going to go for one from off a 5 cylinder diesel 2.5L volvo (or most modernish 2.5L diesel) only reason is because i know it has been done before. as said, i wont be running it at high boost pressures (20 to 22psi max!)
the turbo is called "GT2052v" they are not that expensive and can be restored pretty easy by just getting a replacement cartridge with spindle and wheels attached. can the turbo for about 50 and a replacement cartridge for 70-100. the veins never seem to ware out on these but they have been known to get clogged up. i will clean it all up anyway in my sonic bath then measure any gaps in the veins with a feeler gauge to see how worn it is, but like i say.. ive never seen the veins needing to be replaced on this particular turbo yet, its always the spindle that gets play in it over time
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well see you all next week!
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Old 04-10-2016   #44
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Re: John Dragon Man's Citroen BX Diesel Estate

and here they are!

this is what 243.96 worth of brand new piping for the BX looks like

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Old 08-10-2016   #45
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Re: John Dragon Man's Citroen BX Diesel Estate

I have swapped over the 2 front caliper feed pipes, they looked the worst out of all of them, and i have managed to completely rebuild the brakes up on the drivers side front. with new pipes, caliper and disc it does look pretty good. the other side is a little bit more difficult as the caliper never came with the brake pad bracket.. (bit the brake pads sit in). i will swap it over once i (surprise surprise) get the special pentagon head bolt socket to undo the old caliper and install on the new. another PSA great design to stop people fixing there own cars no doubt.

the pipe kit does not include every pipe sadly. i really wanted to change every pipe.. however since i have jetwashed them they look to only have slight surface rusting on them.. i think if i was to paint them with the same paint i used on the engine (but a different colour), i think they would be OK. my peace of mind however will still be a little weary... it will just make me so i will not drive it fast. not that i ever do drive fast.

sadly i am also having clutch issues. the one i got for it is not the right size. its too small! dont think i can return it sadly. i weighed the flywheels of both the engines before i fit them to the engine.. and i decided to use the more heavy one. both are the same diameter, but they have different bolt patterns.

anyway i decided to sort out that snapped off heater matrix tap. now i hear that if you even breath on these things, they start to leak so i decided to make a good one out of the 2 i have. the one that was snapped still had nice soft rubber o rings so i took the whole thing apart to swap the seals over and give it a clean. you do have to drill the heads off 2 rivets located in the bolt holes to actually split the thing apart, interesting design that really could have done with 2 more bolts helping hold the centre in, but i am sure with a little help of some instant gasket and the newer old seals i think i will not have it leak. this looks like one of those things where if you were to over tighten it, it would cause the whole thing to arch and leak from the middle so that may be a cause if you are having issues with it.. another thing you may be able to do is use some kind of clamp to hold it together.. anyway..

heres the pictures:













sadly i forgot to take a picture of it built up, but i have not installed it yet so i will do that next Thursday.

i have also taken the old heater matrix out. not that there was anything wrong with it, but i managed to buy a new one for next to nothing so may as well fit that while i am at it!

another job almost done.. one more step to getting the engine in..
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