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Chris H
Forum Moderator
Joined: 02 Mar 2004
Posts: 19978
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| Posted:
Wed Aug 23, 2006 2:15 pm |
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26th November 2005
When I was at the scrapyard for the blue 3 door this was there. Iain and Roddy saw it and agreed it was a nice car, which it was it also had money thrown at it recently, new tyres, exhaust, alternator etc...
However I knew it was a can of worms and needed work. Not a problem if your getting paid to sort them but I knew it was a money pit. It had plenty of rust on it as well, always a good sign 
I noted it had a new alternator which project Y required, so went back with my sister a few days later.
She was on the phone to mum and talked her into buying it. The car cost £80 or something ridiculous, I told her don't get it, Amber is a witness to all of this. But they went ahead with it anyway and I was the fella to do the work.
Anyway once my sister and I pushed it out of the yard we had a problem it was a non runner, the previous owner had scrapped it for a reason. The headgasket had gone pop. But me being me got it running and drove it the 5 miles home fine.
Only slight issue was the whole car steamed up due to a burst heater matrix.
Anyway car back at base
[img:567:425:7ee8335c2d]http://www.renault-turbo.com/chris/grey%205/project%205%2001.jpg[/img:7ee8335c2d]
nice hole in the A pillar
[img:567:425:7ee8335c2d]http://www.renault-turbo.com/chris/grey%205/project%205%2002.jpg[/img:7ee8335c2d]
lovely flush fitting seals
[img:567:425:7ee8335c2d]http://www.renault-turbo.com/chris/grey%205/project%205%2003.jpg[/img:7ee8335c2d]
other side just starting to go
[img:567:425:7ee8335c2d]http://www.renault-turbo.com/chris/grey%205/project%205%2004.jpg[/img:7ee8335c2d]
the header tank
[img:425:567:7ee8335c2d]http://www.renault-turbo.com/chris/grey%205/project%205%2005.jpg[/img:7ee8335c2d]
[img:567:425:7ee8335c2d]http://www.renault-turbo.com/chris/grey%205/project%205%2006.jpg[/img:7ee8335c2d]
[img:567:425:7ee8335c2d]http://www.renault-turbo.com/chris/grey%205/project%205%2007.jpg[/img:7ee8335c2d]
[img:425:567:7ee8335c2d]http://www.renault-turbo.com/chris/grey%205/project%205%2008.jpg[/img:7ee8335c2d]
[img:425:567:7ee8335c2d]http://www.renault-turbo.com/chris/grey%205/project%205%2009.jpg[/img:7ee8335c2d]
1st day purchases
heater matrix
[img:567:425:7ee8335c2d]http://www.renault-turbo.com/chris/grey%205/5%20matrix%2001.jpg[/img:7ee8335c2d]
and wiper blades
[img:567:425:7ee8335c2d]http://www.renault-turbo.com/chris/grey%205/5%20wiper%20blades%2001.jpg[/img:7ee8335c2d] |
Last edited by Chris H on Wed Oct 04, 2006 12:08 pm; edited 1 time in total |
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Chris H
Forum Moderator
Joined: 02 Mar 2004
Posts: 19978
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| Posted:
Wed Aug 23, 2006 2:26 pm |
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27th Nov
I started the strip down to change the heater matrix
[img:567:425:dd0456e4cd]http://www.renault-turbo.com/chris/grey%205/5%20bay%2001.jpg[/img:dd0456e4cd]
stuffed the pipes so the water didn't pour out all over the interior
[img:567:425:dd0456e4cd]http://www.renault-turbo.com/chris/grey%205/5%20matrix%2002.jpg[/img:dd0456e4cd]
note the difference between the matrixes, the new one took some modification to fit
[img:567:425:dd0456e4cd]http://www.renault-turbo.com/chris/grey%205/5%20matrix%2003.jpg[/img:dd0456e4cd]
Anyway with that nasty job done I cleaned the interior up a bit.
[img:567:425:dd0456e4cd]http://www.renault-turbo.com/chris/grey%205/5%20interior%2001.jpg[/img:dd0456e4cd]
[img:567:425:dd0456e4cd]http://www.renault-turbo.com/chris/grey%205/5%20interior%2002.jpg[/img:dd0456e4cd]
low mileage means nothing folks!
[img:567:425:dd0456e4cd]http://www.renault-turbo.com/chris/grey%205/5%20mileage.jpg[/img:dd0456e4cd]
these were the old knackered wipers, as you can see they were well past it.
[img:567:425:dd0456e4cd]http://www.renault-turbo.com/chris/grey%205/5%20old%20wipers.jpg[/img:dd0456e4cd]
As we know the headgasket was gone, this is the radiator cap removed (the C-type engines radiator end tanks have a seperate cap on them)
[img:567:425:dd0456e4cd]http://www.renault-turbo.com/chris/grey%205/5%20rad%2001.jpg[/img:dd0456e4cd]
[img:567:425:dd0456e4cd]http://www.renault-turbo.com/chris/grey%205/5%20rad%2002.jpg[/img:dd0456e4cd]
this is what freely poured out of the radiator!
[img:567:425:dd0456e4cd]http://www.renault-turbo.com/chris/grey%205/5%20rad%2003.jpg[/img:dd0456e4cd]
fins were almost none existant
[img:567:425:dd0456e4cd]http://www.renault-turbo.com/chris/grey%205/5%20rad%2004.jpg[/img:dd0456e4cd]
this is the top hose, the C type has the stat in the hose itself, covered in sludge
[img:567:425:dd0456e4cd]http://www.renault-turbo.com/chris/grey%205/5%20top%20hose%2001.jpg[/img:dd0456e4cd]
Anyway I hate dirty cars and to take my mind off the fact it was a total bin I washed the beast.
[img:567:425:dd0456e4cd]http://www.renault-turbo.com/chris/grey%205/5%20washed%2001.jpg[/img:dd0456e4cd]
popped the seal back in on the screen
[img:425:567:dd0456e4cd]http://www.renault-turbo.com/chris/grey%205/5%20washed%2002.jpg[/img:dd0456e4cd]
[img:425:567:dd0456e4cd]http://www.renault-turbo.com/chris/grey%205/5%20washed%2003.jpg[/img:dd0456e4cd]
[img:567:425:dd0456e4cd]http://www.renault-turbo.com/chris/grey%205/5%20washed%2004.jpg[/img:dd0456e4cd]
[img:425:567:dd0456e4cd]http://www.renault-turbo.com/chris/grey%205/5%20washed%2005.jpg[/img:dd0456e4cd]
Looks ok, but then again everything looks ok with a good wash. I also fitted the 4th wheel trim, it was inside the car when we got it. |
Last edited by Chris H on Wed Oct 04, 2006 12:14 pm; edited 1 time in total |
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Chris H
Forum Moderator
Joined: 02 Mar 2004
Posts: 19978
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| Posted:
Wed Aug 23, 2006 2:41 pm |
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28th Nov
This fairy tale keeps getting better, had a look under it
snapped road spring
[img:567:425:152df12cd3]http://www.renault-turbo.com/chris/grey%205/5%20broken%20spring%2001.jpg[/img:152df12cd3]
the broken part
[img:567:425:152df12cd3]http://www.renault-turbo.com/chris/grey%205/5%20broken%20spring%2002.jpg[/img:152df12cd3]
I removed the crappy mudflaps as these cause more hassle than they are worth also 1 of the rear ones was missing
[img:567:425:152df12cd3]http://www.renault-turbo.com/chris/grey%205/5%20mudflap%2001.jpg[/img:152df12cd3]
[img:567:425:152df12cd3]http://www.renault-turbo.com/chris/grey%205/5%20mudflap%2002.jpg[/img:152df12cd3]
[img:425:567:152df12cd3]http://www.renault-turbo.com/chris/grey%205/5%20mudflap%2003.jpg[/img:152df12cd3]
I knew the flaps would be hidding some horror so popped off the wing trim
[img:425:567:152df12cd3]http://www.renault-turbo.com/chris/grey%205/5%20drivers%20wing%2001.jpg[/img:152df12cd3]
sure enough after some gentle probing
[img:567:425:152df12cd3]http://www.renault-turbo.com/chris/grey%205/5%20drivers%20wing%2002.jpg[/img:152df12cd3]
I removed the bumper to get a view of the front
[img:567:425:152df12cd3]http://www.renault-turbo.com/chris/grey%205/5%20drivers%20wing%2003.jpg[/img:152df12cd3]
front bumper off
[img:567:425:152df12cd3]http://www.renault-turbo.com/chris/grey%205/5%20no%20bumper.jpg[/img:152df12cd3]
the front slam panel wasn't to clever looking
[img:567:425:152df12cd3]http://www.renault-turbo.com/chris/grey%205/5%20slam%2001.jpg[/img:152df12cd3]
[img:567:425:152df12cd3]http://www.renault-turbo.com/chris/grey%205/5%20slam%2002.jpg[/img:152df12cd3]
[img:567:425:152df12cd3]http://www.renault-turbo.com/chris/grey%205/5%20slam%2003.jpg[/img:152df12cd3]
I also cleaned out the large hole in the A pillar as it had a lot of debris in it. I also removed the outer part of the windscreen rubber.
[img:567:425:152df12cd3]http://www.renault-turbo.com/chris/grey%205/5%20hole%20cleaned%20out.jpg[/img:152df12cd3]
The headgasket was coming off so I jacked the car up to get to the exhaust and removed the drivers wheel, newish brake discs
[img:567:425:152df12cd3]http://www.renault-turbo.com/chris/grey%205/5%20new%20discs.jpg[/img:152df12cd3]
some slight rust on the metal brake pipe spotted as well
[img:567:425:152df12cd3]http://www.renault-turbo.com/chris/grey%205/5%20rusty%20brake%20pipe.jpg[/img:152df12cd3]
Anyway to the head removal
[img:425:567:152df12cd3]http://www.renault-turbo.com/chris/grey%205/5%20head%20removal%2001.jpg[/img:152df12cd3]
number 2 cylinder plug removed, thats not gonna work to well...
[img:567:425:152df12cd3]http://www.renault-turbo.com/chris/grey%205/5%20head%20removal%2002.jpg[/img:152df12cd3]
head off, look at the sludge
[img:425:567:152df12cd3]http://www.renault-turbo.com/chris/grey%205/5%20head%20removal%2003.jpg[/img:152df12cd3]
[img:425:567:152df12cd3]http://www.renault-turbo.com/chris/grey%205/5%20head%20removal%2004.jpg[/img:152df12cd3]
headbolts, rockers and shaft and pushrods
[img:567:425:152df12cd3]http://www.renault-turbo.com/chris/grey%205/5%20head%20removal%2005.jpg[/img:152df12cd3]
head complete with manifolds off
[img:425:567:152df12cd3]http://www.renault-turbo.com/chris/grey%205/5%20head%20removal%2006.jpg[/img:152df12cd3]
[img:425:567:152df12cd3]http://www.renault-turbo.com/chris/grey%205/5%20head%20removal%2007.jpg[/img:152df12cd3]
head end plate removed (c-type head has the pump fitted at he other end in ren 4's etc)
[img:567:425:152df12cd3]http://www.renault-turbo.com/chris/grey%205/5%20head%20removal%2008.jpg[/img:152df12cd3]
manifolds off
[img:425:567:152df12cd3]http://www.renault-turbo.com/chris/grey%205/5%20head%20removal%2009.jpg[/img:152df12cd3] |
Last edited by Chris H on Wed Oct 04, 2006 12:23 pm; edited 1 time in total |
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Chris H
Forum Moderator
Joined: 02 Mar 2004
Posts: 19978
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| Posted:
Wed Aug 23, 2006 2:58 pm |
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30th Nov
Now I had the not to nice task of trying to clean the water jacket of sludge, this entailed a lot of soaking and even sucking out with a length of hose
[img:567:425:297183077f]http://www.renault-turbo.com/chris/grey%205/5%20block%20waterway%2001.jpg[/img:297183077f]
[img:567:425:297183077f]http://www.renault-turbo.com/chris/grey%205/5%20block%20waterway%2002.jpg[/img:297183077f]
I also had the task of removing the water pump from the cylinder head, simple in theory not so in practice!
the head actually broke off of this bolt
[img:567:425:297183077f]http://www.renault-turbo.com/chris/grey%205/5%20broken%20stud%2001.jpg[/img:297183077f]
another broken stud out
[img:567:425:297183077f]http://www.renault-turbo.com/chris/grey%205/5%20broken%20stud%2002.jpg[/img:297183077f]
another broken bolt, it came out easy enough
[img:567:425:297183077f]http://www.renault-turbo.com/chris/grey%205/5%20broken%20stud%2003.jpg[/img:297183077f]
the dodgy cylinders chamber
[img:567:425:297183077f]http://www.renault-turbo.com/chris/grey%205/5%20head%20chamber%2001.jpg[/img:297183077f]
I gave the head a really good clean
[img:567:425:297183077f]http://www.renault-turbo.com/chris/grey%205/5%20head%20chamber%2002.jpg[/img:297183077f]
this pic shows the bowl area, piss poor, I can't even remember if I did any headwork on this, I think I may have
[img:567:425:297183077f]http://www.renault-turbo.com/chris/grey%205/5%20valve%20bowl%2001.jpg[/img:297183077f]
[img:567:425:297183077f]http://www.renault-turbo.com/chris/grey%205/5%20valve%20bowl%2002.jpg[/img:297183077f]
[img:567:425:297183077f]http://www.renault-turbo.com/chris/grey%205/5%20valve%20bowl%2003.jpg[/img:297183077f]
2nd December
The inlet manifold
[img:567:425:297183077f]http://www.renault-turbo.com/chris/grey%205/5%20inlet%20man%2001.jpg[/img:297183077f]
the manifold is joined to the exhaust manifold via the EGR system, nightmare
[img:567:425:297183077f]http://www.renault-turbo.com/chris/grey%205/5%20inlet%20man%2002.jpg[/img:297183077f]
the throttle body, you can see where the gasses from the exhaust go to mix with the inlet charge
[img:425:567:297183077f]http://www.renault-turbo.com/chris/grey%205/5%20inlet%20man%2003.jpg[/img:297183077f]
The headgasket set we got had the wrong headgasket on it, I had looked at the pistons and they were about 0.3mm below the top of the liner, so even though the gasket was to small I thought it would be ok and fitted it
[img:425:567:297183077f]http://www.renault-turbo.com/chris/grey%205/5%20new%20hg%2001.jpg[/img:297183077f]
I still had to finish the water pump, strip it down and clean it out
side that mates to the head
[img:567:425:297183077f]http://www.renault-turbo.com/chris/grey%205/5%20water%20pump%2001.jpg[/img:297183077f]
other half
[img:567:425:297183077f]http://www.renault-turbo.com/chris/grey%205/5%20water%20pump%2002.jpg[/img:297183077f]
note the whitish vertical line on the right above the bottom hose outlet
[img:567:425:297183077f]http://www.renault-turbo.com/chris/grey%205/5%20water%20pump%2003.jpg[/img:297183077f]
the impellar
[img:567:425:297183077f]http://www.renault-turbo.com/chris/grey%205/5%20water%20pump%2004.jpg[/img:297183077f]
the pump body bolts, again a bit of a task to remove!
[img:567:425:297183077f]http://www.renault-turbo.com/chris/grey%205/5%20water%20pump%2005.jpg[/img:297183077f]
that whitish line close up
[img:567:425:297183077f]http://www.renault-turbo.com/chris/grey%205/5%20water%20pump%2006.jpg[/img:297183077f]
a small passage that was blocked by ally corrosion - the white stuff!
[img:567:425:297183077f]http://www.renault-turbo.com/chris/grey%205/5%20water%20pump%2007.jpg[/img:297183077f]
note poor casting, easy to mod to increase water flow, I never bothered
[img:425:567:297183077f]http://www.renault-turbo.com/chris/grey%205/5%20water%20pump%2008.jpg[/img:297183077f] |
Last edited by Chris H on Wed Oct 04, 2006 12:31 pm; edited 1 time in total |
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Chris H
Forum Moderator
Joined: 02 Mar 2004
Posts: 19978
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| Posted:
Wed Aug 23, 2006 3:10 pm |
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6th Dec
poked a new hole under where the coolant expansion tank lived, note new radiator
[img:425:567:3e8aac3a37]http://www.renault-turbo.com/chris/grey%205/5%20slam%20hole.jpg[/img:3e8aac3a37]
The bumper had been off all the time, and now it was time to refit it, I had to clear up the fixings a bit first
[img:567:425:3e8aac3a37]http://www.renault-turbo.com/chris/grey%205/5%20bumper%20refit%2001.jpg[/img:3e8aac3a37]
[img:567:425:3e8aac3a37]http://www.renault-turbo.com/chris/grey%205/5%20bumper%20refit%2002.jpg[/img:3e8aac3a37]
[img:567:425:3e8aac3a37]http://www.renault-turbo.com/chris/grey%205/5%20bumper%20refit%2003.jpg[/img:3e8aac3a37]
these daft blocks had caused the above corrosion by trapping water!
[img:567:425:3e8aac3a37]http://www.renault-turbo.com/chris/grey%205/5%20bumper%20refit%2004.jpg[/img:3e8aac3a37]
block fitted
[img:567:425:3e8aac3a37]http://www.renault-turbo.com/chris/grey%205/5%20bumper%20refit%2005.jpg[/img:3e8aac3a37]
Before the bumper went on the horn never worked and heres why
[img:567:425:3e8aac3a37]http://www.renault-turbo.com/chris/grey%205/5%20horn.jpg[/img:3e8aac3a37]
stuck another on and it was sorted
The bumper went on, no pics but its not hard to imagine...
Anyway the engine was knocking and I knew what it was, it was that crappy headgasket, rod stretch at higher revs allowed the pistons to hit the gasket, not good, so I spent £8 on a new correct headgasket and pulled the head - again!
Despite the short running time since the headgasket was done the first time it had made my shiny chambers dirty, still they were equally dirty which is good as it meant all cylinders were firing happily.
[img:425:567:3e8aac3a37]http://www.renault-turbo.com/chris/grey%205/5%20head%20off%20again%2001.jpg[/img:3e8aac3a37]
[img:425:567:3e8aac3a37]http://www.renault-turbo.com/chris/grey%205/5%20head%20off%20again%2002.jpg[/img:3e8aac3a37]
you can see the shiny part where the piston had been hitting
[img:567:425:3e8aac3a37]http://www.renault-turbo.com/chris/grey%205/5%20head%20off%20again%2003.jpg[/img:3e8aac3a37]
[img:567:425:3e8aac3a37]http://www.renault-turbo.com/chris/grey%205/5%20head%20off%20again%2004.jpg[/img:3e8aac3a37]
damage to the gasket
[img:567:425:3e8aac3a37]http://www.renault-turbo.com/chris/grey%205/5%20head%20off%20again%2005.jpg[/img:3e8aac3a37]
When I put the head back on the engine revved its arse off, now I have seen 5's do this before and no one has a cure for it that doesn't involve replacing everything injection related! The idle is around 3krpm!
I started in the most obvious area, the ICV as it was noisy and sticky in action
[img:567:425:3e8aac3a37]http://www.renault-turbo.com/chris/grey%205/5%20icv%2001.jpg[/img:3e8aac3a37]
[img:567:425:3e8aac3a37]http://www.renault-turbo.com/chris/grey%205/5%20icv%2002.jpg[/img:3e8aac3a37]
[img:567:425:3e8aac3a37]http://www.renault-turbo.com/chris/grey%205/5%20icv%2003.jpg[/img:3e8aac3a37]
[img:567:425:3e8aac3a37]http://www.renault-turbo.com/chris/grey%205/5%20icv%2004.jpg[/img:3e8aac3a37]
Well after it was cleaned up it was quiet and no longer sticky in action, still never cured the high idle though |
Last edited by Chris H on Wed Oct 04, 2006 12:37 pm; edited 1 time in total |
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Chris H
Forum Moderator
Joined: 02 Mar 2004
Posts: 19978
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| Posted:
Wed Aug 23, 2006 3:17 pm |
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8th Dec
In case you can't tell I really hated this car, it had already taken about £200 of my mums money, matrix, wipers, radiator, headgasket set, cost of the car etc I was trying to get it sorted as she had sunk the cash into it despite my protests not to!
The EGR valve was the next area of attack for the high idle issue
[img:567:425:e03ab0dd42]http://www.renault-turbo.com/chris/grey%205/5%20egr%2001.jpg[/img:e03ab0dd42]
[img:567:425:e03ab0dd42]http://www.renault-turbo.com/chris/grey%205/5%20egr%2002.jpg[/img:e03ab0dd42]
it was fine, sealed up perfectly etc.
a new manifold to TB gasket might help as the old one was iffy
[img:567:425:e03ab0dd42]http://www.renault-turbo.com/chris/grey%205/5%20new%20tb%20gasket%2001.jpg[/img:e03ab0dd42]
as you can see chunks were missing
[img:567:425:e03ab0dd42]http://www.renault-turbo.com/chris/grey%205/5%20new%20tb%20gasket%2002.jpg[/img:e03ab0dd42]
14th Dec I was looking at the old parts, the dodgy 1st replacement headgasket
[img:425:567:e03ab0dd42]http://www.renault-turbo.com/chris/grey%205/5%20hg%20number%202.jpg[/img:e03ab0dd42]
the original hg
[img:425:567:e03ab0dd42]http://www.renault-turbo.com/chris/grey%205/5%20orig%20hg.jpg[/img:e03ab0dd42]
the old radiator, what a mess that was
[img:567:425:e03ab0dd42]http://www.renault-turbo.com/chris/grey%205/5%20old%20rad%2001.jpg[/img:e03ab0dd42]
no fins
[img:567:425:e03ab0dd42]http://www.renault-turbo.com/chris/grey%205/5%20old%20rad%2002.jpg[/img:e03ab0dd42]
I had better things to deal with and left it at that for a wee while. |
Last edited by Chris H on Wed Oct 04, 2006 12:40 pm; edited 1 time in total |
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Chris H
Forum Moderator
Joined: 02 Mar 2004
Posts: 19978
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| Posted:
Wed Aug 23, 2006 3:28 pm |
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23rd Dec
I pulled the highly complex injection loom off the engine to check it for damage and poor continuity. It checked out fine
[img:567:425:69f9af8e67]http://www.renault-turbo.com/chris/grey%205/5%20injection%20loom.jpg[/img:69f9af8e67]
So the TB was next to get a good going over.
I should add that unplugging the MAP sensor tube and leaving it open to atmosphere made the idle drop and idle reasonably well, the MAP sensor worked as it should so that wasn't the problem, if you sucked on the map sensor stub the revs rocketed up again.
Anyway the TB, look at that massive throttle plate
[img:567:425:69f9af8e67]http://www.renault-turbo.com/chris/grey%205/5%20tb%20apart%2001.jpg[/img:69f9af8e67]
thats a 20 pence piece, shows how small the plate was!
[img:567:425:69f9af8e67]http://www.renault-turbo.com/chris/grey%205/5%20tb%20apart%2002.jpg[/img:69f9af8e67]
injector
[img:567:425:69f9af8e67]http://www.renault-turbo.com/chris/grey%205/5%20tb%20apart%2003.jpg[/img:69f9af8e67]
this is where a TPS sensor mounts, only the auto version of this engine had a TPS though!
[img:567:425:69f9af8e67]http://www.renault-turbo.com/chris/grey%205/5%20tb%20apart%2004.jpg[/img:69f9af8e67]
the injection system on this engine is laughable and probably the reason why its so hard to fix, it uses a switch for idle and a switch for max throttle, it relied on map sensor for load info alone but that didn't work! The more I think about it the more I think it was the ECU that was damaged, a voltage spike or similar.
I was sick of looking at its engine so looked at its wing, which had gotten worse in the few weeks the car was there.
So I pulled the wing off
[img:567:425:69f9af8e67]http://www.renault-turbo.com/chris/grey%205/5%20wing%20off%2001.jpg[/img:69f9af8e67]
hole on the wing from inside the wing
[img:425:567:69f9af8e67]http://www.renault-turbo.com/chris/grey%205/5%20wing%20off%2002.jpg[/img:69f9af8e67]
mud build up in the wing
[img:425:567:69f9af8e67]http://www.renault-turbo.com/chris/grey%205/5%20wing%20off%2003.jpg[/img:69f9af8e67]
It was pretty much then I vowed not to touch the heap again. I tried a few more times to get it to run right as my mum asked me to. But I eventually talked her round to the fact it was a bin of crap and she agreed to let it go despite losing heavily finacnially on it
So in February 2006 I took a few pics and here sone of the history and the receipts for the parts
[img:567:378:69f9af8e67]http://www.renault-turbo.com/chris/grey%205/5%20history.jpg[/img:69f9af8e67]
The car was listed on ebay and sold for £35. The fees etc came to £25 so we got £10 for the car.
I was glad it was gone, I had told her from the start this would happen but she never listened.
So that was the end of project disaster. |
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