Technical Rebuilding the Multijet - Video

[Bdamit]

Hello all, I have been busy in my kitchen with the Diesel multijet rebuild. This car is in decent condition, but more recently was poorly treated. It has only ever done short journeys throughout its life and was in need of a good de-carbon session. I've never seen anything so clogged with muck since the drains backed up, but that is another story!

Well, I limped this one back home with all manner of CEL warnings, mostly emissions systems were going haywire. I'm not surprised, and neither shall you be if you watch my video on the disassembly, clean and rebuild. It is not an instructional video, but could well come in handy for anyone who wishes to find their way around this little engine.

I hope you enjoy, forgive the generic relaxing music and slightly erratic colour balance.

 

[AnthonyH]

Nice job, well done.

 

[DaveMcT]

it sounds a lot like mine. The timing chain had failed, so I got the car very cheap. The inlet manifold was almost totally blocked with soot and grease and turbo was rattling in its bearings. Internal wear was minimal so It got a new set of rings and a light cylinder hone. Cam chain lifters and rocker were all replaced. Turbo core was replaced and after some starting problems I fitted Bosch remanufactured injectors and a remanufactured fuel pump. Not a cheap job but it's still a low cost car and now going well.

Top end work "can" be done with engine in the car, but I strongly recommend removing the engine and gearbox lump. The additional work is not huge and you can get to everything so much more easily. Even seemingly easy stuff like air pump and fuel injection pump can bite - use the wrong length bolt"" and you will crack the cam carrier (ask how I know). Mine had a nearly new clutch, but I had problems reconnecting the gearbox. After pulling the box off for the second time (to check friction plate alignment - again) I noticed a rattle. The clutch centre was falling apart WTF! I ordered a new clutch kit from S4P and received a much heavier unit. I assume the old "new" clutch had been a petrol version. This time, the gearbox almost fell into place.

** The correct bolts for air pump look like any other M8 socket head, but are actually a special length.