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Symio: Missus' 1.6 16v CC: el.PAS, cambelt, clutch, and more
-> Project Cars

#1: Symio: Missus' 1.6 16v CC: el.PAS, cambelt, clutch, and more Author: Sim, Location: Bristol PostPosted: Sat Dec 16, 2017 3:41 pm
    ----
Back in 2016 been pondering what kind of first car could my missus have. Knowing the colour she'd want in, weighing fun, garageability, ICE, 206, newish, and few other factors, after numerous candidates I decided to sneak out to a salvage yard and bring a CC back to the 2nd life:

 


Boxes ticked:
☑ Black is the new black
☑ Well preserved leather interior
☑ Fun drop top for summers
☑ Repairable
☑ JBL sound system as optional extra from factory (including elongated sub in the boot)
☑ It's a 206! (really..)
☑ Year 2007
☑ 62,700 on the clock
☑ £650

The damage done was this side scrape (looks worse than it is):

 


and a failed power steering pump (from running dry) -- it had lost the fluid when its pressure sensor (aiding the ESP/ASR system) blew apart:

 


In your opinion, what could have caused this to happen? Trapped air when low on fluid? Soaring temperatures of heatwaves in summer of '16? Confused

After hiding Symio at the unit, sourcing the spares, and repairing when work on the garage permitted (or not), one year later this CC had been brought up to a somewhat presentable state and revealed to my unaware missus for her birthday:

 

Last edited by Sim on Fri Feb 22, 2019 2:47 pm; edited 2 times in total

#2: Re: Symio: Missus' 1.6 16v CC: ePAS & crude dent repair Author: Sim, Location: Bristol PostPosted: Mon May 14, 2018 12:35 pm
    ----
Fast-forward to the last weekend, Project Binky style bracket done:
 


Bolt-on pump:
 


Run-in tests to commence tonight, can't wait! \o/

--
Word-of-warning several months later: this is too close to the exhaust manifold, will overheat and develop a leak. So either be crafty with a heatshield solution, or go down the route of re-routing the pipes Confused (meaning a visit to hydraulics company)

Last edited by Sim on Sat Feb 23, 2019 1:11 pm; edited 1 time in total

#3: Re: Symio: Missus' 1.6 16v CC: ePAS & crude dent repair Author: Sim, Location: Bristol PostPosted: Mon May 21, 2018 2:48 pm
    ----
You can see from previous photo that cambelt sprockets are exposed, decided to tidy that up, which meant sprockets off, meaning new cambelt, meaning new waterpump, meaning coolant change, meaning "Hal fixing a lightbulb". Was due for cambelt anyway due to no service history from that salvage yard and the mileage.

 


Yet absolutely loved the engine's designation cast print proudly shining!

#4: Re: Symio: Missus' 1.6 16v CC: ePAS & crude dent repair Author: Sim, Location: Bristol PostPosted: Mon May 21, 2018 11:25 pm
    ----
TU5JP4 (1.6 16v NFU) cambelt replacement instructions are not in 206 Haynes manual, but they are in the 307 one Razz ..and Autodata is your friend, always. As well as this guy.

Locking up the crankshaft was another pain point, Haynes showing even exhaust manifold removed for easier access. But by the looks of it, oil filter might have to come off, especially if the hole into the flywheel has gunked up with rust.

The middle torx bolt that fixes the inner cambelt cover in place had a small oil leak. I realised it had't been done up properly! Or had come undone due to the oil collecting behind it.

 


Looks like the cast has been machined up to the very area of the oil gallery itself, so I dried it up as much as possible, dabbed some thread locker, tightened to 22 Nm and hope the oil'll never come back through Smile

The amount of cursing and bashing that the old water pump took was immense. It just caked up from all possible deposits within + time. Initial impactful prying resulted in this: Very Happy

 


Finally found an angle where to place the crowbar and leverage it out, to be honest wouldn't know how to proceed, had the cambelt inner cover was still on (that poor plastic wouldn't take the pressure for sure).

#5: Re: Symio: Missus' 1.6 16v CC: ePAS, cambelt & crude dent repair Author: Sim, Location: Bristol PostPosted: Mon May 28, 2018 12:58 pm
    ----
That rewarding engine sound when you don't hear misfires or worse clunking after your first cambelt change Very Happy youtu.be/FHIE-N3Qr5M

#6: Re: Symio: Missus' 1.6 16v CC: ePAS, cambelt & crude dent re Author: Sim, Location: Bristol PostPosted: Fri Jun 01, 2018 6:24 am
    ----
What the hell did just happen Click here?

Linking out due to some gruesome imagery if misinterpreted Smile

#7: Re: Symio: Missus' 1.6 16v CC: ePAS, cambelt & crude dent re Author: Sim, Location: Bristol PostPosted: Wed Jun 13, 2018 4:15 pm
    ----
With all original Citroen ePAS pump loom in place (relay on the far left of the photo), and a new earthpoint reusing a hole in the radiator housing, this part of the project concluded:

 


The MOT bucket list was surprisingly short, to replace the O/S/F wishbone.
What could possibly go wrong?

Well, one of the wishbone/subframe steel bolts had seized in, essentially fused itself with the aluminium tubing that sits inside the bush.
So there's no way of getting the bugger out, except for dropping subframe or trying some whacky grinding...
Has anyone been in such a messy situation before? Smile

#8: Re: Symio: Missus' 1.6 16v CC: ePAS, cambelt & crude dent re Author: Sim, Location: Bristol PostPosted: Thu Jul 12, 2018 10:56 am
    ----
The seized wishbone bolt has surrendered to the slide hammer, subframe slightly bowed out, but went back in place as the new bolt got the grip.

One week after Pugfest, CarPro's PERL is still holding up nicely, not having gone overboard with it either way
 

#9: Re: Symio: Missus' 1.6 16v CC: ePAS, cambelt & crude dent re Author: Sim, Location: Bristol PostPosted: Sat Sep 15, 2018 10:56 pm
    ----
The clutch biting point has always been very high since we got the car, and even when it doesn't slip, I shouldn't wait for it to (i.e. not driven to "distraction")

Another worrisome bit was seeing the drops of oil collecting under the bell housing, coming out from where the flywheel is (those bungs would be covered in oil):

 


Oily gunk inside the starter motor only confirmed my suspicion:

 


Tomorrow will be the gearbox drop and all the oily mess will be revealed. Hoping it's the crankshaft/flywheel seal, and won't be a pig of a job to replace it (haven't looked into that yet)

So far just been following 206 Haynes (occasionally glancing into the 307 one as well), didn't need extra pairs of hands, and left the car for the night without the gearbox mount and the rear engine mount.. just hanging in there! (yet well supported above and below) Very Happy

#10: Re: Symio: Missus' 1.6 16v CC: ePAS, cambelt & crude dent re Author: Sim, Location: Bristol PostPosted: Sun Sep 16, 2018 11:49 pm
    ----
Dropping the gearbox revealed the gruesome

 

 


Blue Meanie is ready to be washed (pure coincidence)

 


All spruced up

 

 


Next up: crankshaft seal and new self-locking flywheel bolts from the stealer! After examining the clutch release fork, might get a replacement too from ECP, gotta use the opportunity now that the gearbox has dropped...

#11: Re: Symio: Missus' 1.6 16v CC: ePAS, cambelt & crude dent re Author: Sim, Location: Bristol PostPosted: Fri Oct 05, 2018 6:12 pm
    ----
Here's the deal with the crankshaft seal.. After removing it, luckily no oil was spilling, all of it remained in the sump.
I just tilted the engine as much up as possible by the transmission end, to be sure to be sure Mr. Green
 


New one in from ECP, said Corteco, arrived Elring, good stuff!
 


LUK, a new clutch!
 


Old fork seat has developed a callus, good job I grabbed a new one
 


Release bearing looks re-designed -- only the top bit is spinning (or has it always been like this just to differ from Valeo Smile )
 


The rear engine mount nut retaining clip has fallen apart when undone, luckily the new ones come with nuts embedded (even though service box splits them a-part)
 


Once it was all finally back together, the new clutch felt out of this world. Very easy on the foot, and biting in the middle, just like it should, so I can stop re-learning everytime I hop between the two 206s.

Last edited by Sim on Sat Feb 23, 2019 1:14 pm; edited 2 times in total

#12: Re: Symio: Missus' 1.6 16v CC: ePAS, cambelt & crude dent repair Author: Edward, Location: In the garage PostPosted: Sat Oct 06, 2018 2:29 pm
    ----
Always good to see jobs like this being done.

#13: Re: Symio: Missus' 1.6 16v CC: ePAS, cambelt & crude dent repair Author: Sim, Location: Bristol PostPosted: Mon Oct 22, 2018 12:35 pm
    ----
Edward wrote:
Always good to see jobs like this being done.
Cheers Edward, that is one rewarding and satisfying hobby that we all have, isn't it Smile

Back in September the offside wheel bearing went out of order. To such extent where it even had a play! Such dislodging might have been "helped" by moving the car in the garage with lower arm pinch ball-joint only located in the hub.
Kids, always put the bolt through there, and the hub bolt back on tight, otherwise the tyre and hub will start mangling the whole suspension around your wheel arch when you push the car even a short distance by hand! And Ackermann's turning in his grave...

Coincidentally to the Andrew's Project, parts been ordered (including SNR bearing kit from ECP that comes handy with a new hub nut and an R-clip) and most of them fitted:
 

 

Original track rod end is still in good nick, so will keep the new one for spares, as it straight fits any 206.

Seeing the amount of rust flaking off of the current hub, done some shopping and whaddayaknow, Neat Car Parts on eBay sell brand new ones for £60, which fit CC, GTi, and 2.0 HDi ABS models.
The only difference in cast is that there isn't a bracket to seat the square-head of the pinch bolt for the shock-absorber.
The exposed metal parts are probably the result of post-machining, I've already painted the front of the hub, and will completely cover other areas of the nearside hub when it arrives...read on

Already been driving couple of hundreds of miles with this setup on the offside, no issues
 

so much that the nearside wheel bearing became all envious and started rumbling beyond compare, all the equivalent parts for the nearside been placed on order yesterday, can't wait to fit!

Last edited by Sim on Sat Feb 23, 2019 1:16 pm; edited 1 time in total

#14: Re: Symio: Missus' 1.6 16v CC: ePAS, cambelt & crude dent re Author: Sim, Location: Bristol PostPosted: Fri Oct 26, 2018 4:41 pm
    ----
As soon as the parts came in, took the old hub off to see lots of mash that I'm yet to investigate by taking the bearing apart
 


Decided to spend a bit more time painting over the unprotected bits of this new hub. Yep, you guessed it right, these naked parts already developed a coat of rust on the O/S/F new hub (see previous post).
A before, during, and the afters:
 

 

 

 

 


I didn't go full Monty to spray the whole surface again, just to see how durable the black paint is that it came in (already spotted some bruised bits that I'd then touched up).
The car needs to be back on the road ASAP, which takes part of the fun out... It's all just a playground anyway before the GTi 180 Preservation Society (founded by VorTechS) kicks in full swing.

The final dress rehearsal:
 

 

#15: Re: Symio: Missus' 1.6 16v CC: ePAS, cambelt & crude dent repair Author: dedeno1, Location: SAINT NAZAIRE (FRANCE) PostPosted: Mon Oct 29, 2018 8:35 am
    ----
Good job, it's beautiful

#16: Re: Symio: Missus' 1.6 16v CC: ePAS, cambelt & crude dent repair Author: Edward, Location: In the garage PostPosted: Mon Oct 29, 2018 6:44 pm
    ----
Do you think those hubs are the same as oe peugeot parts? Seems a strange thing for the aftermarket to bother making.

#17: Re: Symio: Missus' 1.6 16v CC: ePAS, cambelt & crude dent repair Author: Sim, Location: Bristol PostPosted: Tue Oct 30, 2018 2:21 pm
    ----
dedeno1 wrote:
Good job, it's beautiful
Thank you Smile
You can imagine how car looks underneath if so much rust munched many top layers of the old hubs.
Next up will be to de-rust and coat the underside before the winter sets in (they were already Salt Spreading the M5 yesterday Sad )

Edward wrote:
Do you think those hubs are the same as oe peugeot parts? Seems a strange thing for the aftermarket to bother making.
It only misses a ridge cutout where the square-head bolt sits, otherwise they look and feel of the same cast. Even the wheel alignment didn't go off with these new knuckles.

Maybe they got hold of an old mould from Coventry and decided to make a few quid, selling it at half the dealer's price. Comes with 1 year warranty, probably shouldn't be worried now if they passed compliance tests for rigidity Very Happy Otherwise aftermarket lower arms would also have horror stories Smile

EDIT: hmm this Neat Car Parts sell new knuckles also for Renaults, Citroens, Fords, Vauxhalls..

#18: Re: Symio: Missus' 1.6 16v CC: ePAS, cambelt & crude dent repair Author: dedeno1, Location: SAINT NAZAIRE (FRANCE) PostPosted: Wed Oct 31, 2018 8:48 am
    ----
Sim wrote:
dedeno1 wrote:
Good job, it's beautiful
Thank you Smile
You can imagine how car looks underneath if so much rust munched many top layers of the old hubs.
Next up will be to de-rust and coat the underside before the winter sets in (they were already Salt Spreading the M5 yesterday Sad )

I imagine, we have a lot of snow in a part of France here !

I'm more and more interested to put rustproof under the 206 every year, like in Canada !

#19: Re: Symio: Missus' 1.6 16v CC: el.PAS, cambelt, clutch, and Author: Sim, Location: Bristol PostPosted: Sat Feb 23, 2019 1:18 pm
    ----
Time for a long overdue update.
Been otherwise busy over past months with prepping the X-Type for the winter roadtrips -- by far the best investment, as I couldn't get stuck in the snow even after deliberate attempts Very Happy

All this means I ran out of time to rustproof the 206, so just gave a good ole wash up-and-under before more saltspreadders kicked in
 


Notice how I went overboard with tyre silk and forgot to remove the excess, which meant another wash soon after DOH!!!
 

Can't be too clean I guess Smile

Few weeks later the electric PAS pump didn't start up, silver lining as I wanted to see what it'd feel like to drive with it off. However I did park round the block and saw the fluid surging up and out of the reservoir. Luckily, the pump started on the next crank, and I could reach the garage at ease.

So everyone who's thinking to simply add a dash switch for their ePAS pumps, think twice as the fluid is still moved about from the steering rack and you might end up with a huge mess in the engine bay Wink I hope some cut-off-bypasses exist for such cases though.

The pump itself developed a leak, as aptly observed by Pez due to being too close to the exhaust manifold, the plastic membrane within warped and started slowly trickling through the reservoir onto the alternator and the drivebelt:
 


I then parked the car for good, so it didn't see more of this winter's salt Smile
Soon after the holidays I ordered an identical electric pump, but it came with the cracked bracket that holds the reservoir, due to ally oxidising and swelling defying all forces that hold it together:
 


Also seeing that it will take too much time making a heatshield, I've sent the pump back (after repairing it for them using the good parts from mine Wink ) and put the power steering back to standard.

Electric pump is much nicer, there are no "flat spots" under engine load/low RPMs, and is a tad stronger than the belt-driven one.
Also you can adjust the pressure valve, to make it stronger or weaker (as explained here)
I'll certainly consider it in my future projects, tucked away from heat sources (yet I still liked the idea of reusing original piping!), and experimenting with the pressure regulator -- use it at your own risk of bursting pipes/seals Wink

Been driving the CC hoping that nothing else will come up and I can put it to rest waiting for missus' driving test, when a nightmare with the front wheel bearing began Evil or Very Mad but that's gonna be in the next thread update Smile

#20: Re: Symio: Missus' 1.6 16v CC: el.PAS, cambelt, clutch, and Author: Sim, Location: Bristol PostPosted: Thu Mar 07, 2019 12:47 pm
    ----
Since replacing the passenger's side hubs and bearings, at some point the car started to feel a bit wander-y.
Quick check revealed quite a bit of play in the brand new bearing (the parts that sandwich it were also brand new!) but no noise/rumbling.

So either I've seated the bearing incorrectly (pressed+tightened), or something's more sinister..

(several Wall Bang s later)

Here are the differences between the old and the new hub assemblies. Don't mind the inner race protruding, it's just one ole knackered bearing Smile :
 

You can see a coat of rust on the cheap paint job of the swivel hub, eyes on Andrew's powder coats now to see how they'll fare.

Still see no difference? Wink
 


The taper of the brand new Febi hub shaft is different, and goes farther up the driveshaft:
 

vs
 


All the more, it is 0.5mm longer altogether than the assumed stock:
 


Thus when you do up the hub nut, you end up "squeezing" the hub shaft rather than the bearing.

Solution would be to wet'n'dry sand the hub down, but c'mon Febi!..
I didn't have time to experiment, so I simply pressed the same bearing and the old hub face, been happily driving since with no play! Twisted Evil

Question though, how come the driver's side's fine if it's using the exact same new parts? I'll keep an eye on that. I'll also need to measure the distance between the pressing surfaces of the driveshaft and the hub face, using the old spares I've got kicking about.

To tick off the list of mechanical niggles, replaced the track rod end which had a knackered dust cap:
 


Now that the car was mechanically sound, it was time to do the tracking (after having swapped front wheels to the rear due to slightly worn outer tyre edge "thanks" to the toe-in):
 


It became a proper delight throwing her about in the B-road corners due to all this extra low-down weight the CC has! Such a shame this been tuned for comfort and I can't get me no lows Very Happy

After spending winter at the unit where loads of metal grinding and sanding took place, car deserved to be decontaminated with Iron-X (this lemon scent really kills the rotten egg bit!), so it turned out to be a Sundae Sunday DOH!!!
 

 


Next I've been toying about adjusting door windows so they shut properly yet don't leak, I tell ya it's a form of art that I found myself far from mastering Smile



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