Car's definitely been testing me lately.
Transmission/clutch issue was just weird. Clutch had been replaced 6K miles ago and had been fine. Didn't remove the gearbox to fit the Quaife diff so clutch hadn't been disturbed. I just couldn't understand why it was behaving as if it was worn out (revs rising with no increase in speed).
I removed the gearbox to have a look at the clutch and diff.
Clutch was fine.
Nothing obviously wrong with the diff.
diff casing was fine.
So, put it all back together and refitted the XSi clutch cable. Same thing
Thought I'd try a manual adjust clutch cable. Put an order in with AutoDoc for a TRW one that matched the OE part number. Hmmmm, what's wrong here?
That'd be a cable for a LHD car then.
Local factor came to the rescue with a Citroen ZX 2.0L 16V manual cable whcih seems to have resolved the issue. No idea what the problem was but I can only assume that the self-adjust mechanism in the Gti6 Dura cable and the XSi Pagid cable were buggered
In with the AutoDoc order were an INA tensioner and idler that actually had INA bearings in them!
Fitted those and noticed oil inside the cam-cover housing
Took the exhaust cam pulley off to inspect the cam-shaft seal and that was all good. Felt down the back of the engine and, oil - the cam carrier, that I'd resealed, was still leaking!
Out came the camshaft. Cleaned all of the mating surfaces up and resealed with Loctite SI 5980 (black one from Halfords) as opposed to the previously used Loctite 5660 (grey one from Halfords). The black one looks to have a better oil resistance.
And last but not least, the heat exchanger that wasn't exchanging the right things.
The GTi6 one's aren't available. Buying used is a lottery so I went on the search for an alternative. The only engine with a heat exchanger that has the inlet/outlet pointing in the right direction is the DW8.
As you can see, it's a bit thinner than the original.
So I had to order the hollow bolt that secures the heat exchanger to the block to go with it. Fortunately they're still available from Peugeot albeit a special order from France.
Supposed to be doing the morning sprint session around Goodwood at RetroRides Weekender next weekend and the car hasn't been driven any distance yet
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