C5 Newbie Exhaust Help!

[alcudia60]

Hi guys,

            I've had my 51 plate 2.2 hdi  c5 for a couple of months now and had a hell of a time. Usual espr and anti pollution faults, even loose injectors and snapped gear cables.

 

I've managed to fix them all but this one has me stumped,

 

Looking at the gear linkage cables today ready to fit a new set next weekend. took the cat and dpf off to get to the heat shield and all went ok. until it came to refitting the cat to the flexi.

I just cant get the clamp to fit right. its so tight under there that I can only get one hand in. and find it impossible to refit it.

 

any ideas would be gratefully received.

[paul.h]

Welcome to the forum.

 

Citroens procedures do not provide much help but when removing the exhaust or cat/dpf, they keep the flexi fastened to the cat and undo the clip at the front end of the flexi but no reason is given for this.

 

If you have time, perhaps you could give a bit of info on the problems you have already sorted.

[alcudia60]

Hi Paul,

. the problems seem to be normal ones that go with the c5.

Various messages popping up. The latest was to change diesel filter.

Turned out not be the filter but a loose injector ( no 1 ). Tightened it with a 7mm Allen key. Also changed air, fuel and oil filter at the same time. I noticed that an anti pollution fault cropped up next. Simply loads of dead leaves in the air intake.

I live in the Highlands so loads of wet weather and leaves everywhere.

 

The main problem has been the gears. After fixing everything yesterday I jumped in and started her up. She sounded sweet. Put her in first and let off the clutch to find no gears. Checked the connection at the box and one cable had snapped. The left one. Not sure which gears this selects.

Ordered a new set from flea bay. ( no decent motor factors for 50 mile and no public transport here.

So today I got under and undid the cat and dog. Moved them out the way and removed the he's shield.

Nothing was disturbed, all cables connected.

Just have to wait until new parts arrive to get her on the road again.

Any info on fitting the cables would be gratefully received.

[paul.h]

The Haynes manual seems to cover the cable replacement and adjustment. If you do not yet have a copy of Haynes then this post has a link to a previous member shenden's back up copy where some pages can be seen. http://www.citroen-owners-club.co.uk/citroen/topic/8163-haynes-manual-for-c5/

[alcudia60]

Quick update.

I now have gears. Quite a simple job really.

Remove the air filter housing, disconnecting all the plugs so that it can be removed completely.

Disconnect the cables from gearbox by depressing the nipple and pulling off the ball joint.

Remove the clips from the cable housing at the aluminum guide block.

Its fiddly but can be done with a small screwdriver.

From inside the car lift the gear stick gator up over the gear knob and cut the small cable tie. Remove gator and gear knob complete.

Undo the 4 x 10mm retaining nuts with a deep socket.

Jack up the car and use axle stands.

Remove the centre exhaust clamp. Drop the cat and dpf by undoing the 2 x 13mm nuts on the cross member.

This is where I went wrong.

I undid the flexi from the cat and find it impossible to reconnect.

Try undoing the top clamp from the flexi and move the complete unit to one side.

Undo the retaining bolts from underside plastic covers and either remove or fold back the heat shield. Its awkward but can be done.

Remove the gear stick unit and cables complete.

Refit new cables and reverse the procedure to refit.

This took me about 3 hours.

[paul.h]

I am pleased you managed to fix this. As you say, it sounds a fiddly job.