Thinking back over the days work made me realise I hadn't fitted the regulator hydraulic hose retainer bracket under the aforementioned missing bolt: quick job, undo the bolt, install the bracket, refit bolt.
The water pump arrived so it was on with timing belt and water pump removal.
As expected the bolts were all seized in and as they screw into the aluminium casing I was very careful to work them out gently, with plenty of lube and loosening and tightening repeatedly until they were free.
I didn't have any taps, or dies, so spent some time cleaning the bolts and casing threads until the bolts could be screwed in by hand only. When fitting I added a trace of copper-slip to avoid any further corrosion issues.
When the pump was removed half the gasket was very stuck to the housing, so I cut it off with a knife blade, then wire bushed, sanded and scraped the face until clean.
Fitting the new pump and gasket is straightforward, though it's useful if you apply non-setting sealing compound to stick the gasket to the water pump to hold it in position.
I fitted this one dry, so it was a bit of a fiddle to ensure the gasket stayed aligned. I didn't want to use grease as the gasket is meant to bond to the metal surface.
Interestingly, the pump being removed is a genuine Citroen one. I can't work out whether it is September '92, or September '02 manufacture. September '92 would correspond with the manufacture of the car.
The timing belt and engine mounts are all back on, awaiting adding coolant.
1992 2.1 Sd Auto Estate
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Dieselman
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Re: 1992 2.1 Sd Auto Estate
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91 3.0 sei M. 4852 EXY Black
92 2.1 sed M. 5740 ECZ Sable Phenicien
92 3.0 V6-24. 5713 EXY Black
92 2.1 sd M. 5685 ENT Blue Sideral
Prev
90 2.1sd M. 5049 EJV Mandarin
92 2.1sd A. 5698 EJV Mandarin
94 2.1sd A. 6218 ERT Triton
91 2.0si M. 5187 EWT White
92 2.1 sed M. 5740 ECZ Sable Phenicien
92 3.0 V6-24. 5713 EXY Black
92 2.1 sd M. 5685 ENT Blue Sideral
Prev
90 2.1sd M. 5049 EJV Mandarin
92 2.1sd A. 5698 EJV Mandarin
94 2.1sd A. 6218 ERT Triton
91 2.0si M. 5187 EWT White
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Dieselman
- Global Moderator
- Posts: 14771
- Joined: Thu Jun 18, 2009 6:44 pm
Re: 1992 2.1 Sd Auto Estate
Coolant added, engine run to temperature and bled of air, also changed the gearbox ATF, which is very worthwhile and should be done every 12,000 miles.
From under the gearbox you access the strainer and drain plug.
To remove the strainer first unbolt the outer cover, then using pliers without serrations, pull the strainer down using one of the support legs. They can be quite stuck in, but keep firmly pulling while wiggling it a bit. The old ATF was dark brown, but didn't smell of burning.
Clean the strainer using petrol, or white spirit, and a brush. this one was surprisingly clean, with not much debris and no metal flakes.
Fit new O rings to the strainer and cover; strainer is 49 * 2mm, cover is 50 * 3mm.
My new O rings were 2.5mm and 3.5mm cross section, and I couldn't make the strainer O ring fit without risk of breaking the strainer, so re-used the old O ring this time, which was still a firm fit.
The drain plug uses a 16mm copper/aluminium washer as the seal.
The gearbox took 3.5 litres of new ATF and appeared at the 80c Max mark, when hot. I'll check it again when in use and fully hot.
to check, run the selector through all the gears, put it back in park, leave the engine running and pull the dipstick.
ATF expands significantly when hot, so the dipstick is marked with 40c and 80c markings.
I pulled the rear wheel arch liners out, wire brushed the dirt out and had a look at body condition. There are four small areas to weld: front wheelhouse outriggers, left rear inner sill, one small patch on left under the car.
The rear of the car is in very good condition, especially for an estate.
There are some areas of damage to the floor and sills, mainly where the car took a bit of a beating when being moved while not running.
From under the gearbox you access the strainer and drain plug.
To remove the strainer first unbolt the outer cover, then using pliers without serrations, pull the strainer down using one of the support legs. They can be quite stuck in, but keep firmly pulling while wiggling it a bit. The old ATF was dark brown, but didn't smell of burning.
Clean the strainer using petrol, or white spirit, and a brush. this one was surprisingly clean, with not much debris and no metal flakes.
Fit new O rings to the strainer and cover; strainer is 49 * 2mm, cover is 50 * 3mm.
My new O rings were 2.5mm and 3.5mm cross section, and I couldn't make the strainer O ring fit without risk of breaking the strainer, so re-used the old O ring this time, which was still a firm fit.
The drain plug uses a 16mm copper/aluminium washer as the seal.
The gearbox took 3.5 litres of new ATF and appeared at the 80c Max mark, when hot. I'll check it again when in use and fully hot.
to check, run the selector through all the gears, put it back in park, leave the engine running and pull the dipstick.
ATF expands significantly when hot, so the dipstick is marked with 40c and 80c markings.
I pulled the rear wheel arch liners out, wire brushed the dirt out and had a look at body condition. There are four small areas to weld: front wheelhouse outriggers, left rear inner sill, one small patch on left under the car.
The rear of the car is in very good condition, especially for an estate.
There are some areas of damage to the floor and sills, mainly where the car took a bit of a beating when being moved while not running.
You do not have the required permissions to view the files attached to this post.
91 3.0 sei M. 4852 EXY Black
92 2.1 sed M. 5740 ECZ Sable Phenicien
92 3.0 V6-24. 5713 EXY Black
92 2.1 sd M. 5685 ENT Blue Sideral
Prev
90 2.1sd M. 5049 EJV Mandarin
92 2.1sd A. 5698 EJV Mandarin
94 2.1sd A. 6218 ERT Triton
91 2.0si M. 5187 EWT White
92 2.1 sed M. 5740 ECZ Sable Phenicien
92 3.0 V6-24. 5713 EXY Black
92 2.1 sd M. 5685 ENT Blue Sideral
Prev
90 2.1sd M. 5049 EJV Mandarin
92 2.1sd A. 5698 EJV Mandarin
94 2.1sd A. 6218 ERT Triton
91 2.0si M. 5187 EWT White