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The Xantia saga continues...

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DocBrown:
Ever started a job and then wished you hadn't...?
Yes, I've now reached that point. You all know my on going saga with the busted cambelt and engine swap on my 1997 Xantia TD. I described how the replacement steering rack from 'The Dark Side' turned out to be grease free so I sorted that out before fitting it today (12th April 2010) Everything was going well, the birds were singing and the sun was out. Until about 2 hours ago when attempting to plumb in the hydraulic pipes to the steering rack -steering pinion valve. Simply put the original pipe unions don't bloody fit the new rack female threaded portions!
As you can see from the pictures, the larger diameter union (top pipe) threaded portion is now too long and will not screw in. It should go in up to the dirty part of the threads but at the moment only goes in two or three threads. Now since the Haynes manual doesn't show squat about the steering rack I can only assume either Citroen modified the design after 1997 or the rack (from well known reconditioner and supplier to trade etc Delco-Remy) is missing something. It came with protective plugs in all the unions so could only check the obvious dimensions and basic type etc but I didn't check to see if the union/pipe connectors were the same. Having said that since the original pipes are still on the car - it would have been a bit awkward to bring them with me.
So I'm going to ask if anyone out there has any images, photos, micro-fiche reader parts descriptions that show what correct pipe unions it should have or whether my pipes need modifying. The supplier only list one power steering rack for the Xantia and stated it should fit 1993 to 1999 Xantias.



 

DocBrown:
Just been onto the Remy Automotive website and they list two part numbers for steering racks for the Citroen Xantia; DSR580 for years 03. 93 to 01. 98 and the DSR1020 for 01. 98 to 04. 03 model years. Since I know my original pipework is in the correct position and in good condition, I can only assume (until I get more info) that either Citroen modified the rack or hydraulics in continuous improvement or my car has had various parts fitted over the years from different model years. Either way I'm at a loss and have had to email Remy to see what differences - if any - there are between the two part numbers.
Normally steering rack replacement is a comparitively straight forward procedure - except when the word Citroen Xantia is in the same sentence. I'm normally a big fan of hydraulic suspended Citroens but today I'm not....

neo:
I suppose it's possible that it could be a recon - recon unit, IE: perhaps it got sent in for as a refurb with a broken pipe fitting, and they have redrilled and tapped it to a different size?

DocBrown:
That's a good point.
This morning I checked the union nut thread pitch on the original pipes that should feed into the rack and they're 1.5mm and 1.25mm pitch. In the photo, the lower pipe should sit snuggly inside the orifice of the port and then has a seal surrounding the pipe just under the bulge. The union nut then clamps everything together. However this lower pipe doesn't fit as it looks like the port diameter is smaller than the end of the pipe. As for the upper pipe and union the thread pitch is different to the female part on the rack plus it's too shallow compared to the length of the union nut and flared end of the pipe. Phoned Remy today and they list two different racks for the Xantia; the DSR580 and DSR1020. According to Remy the only differences are one type of rack has the gear linkage bracket on the rack and the other type doesn't. Xantia's either have gearbox shift linkage brackets on the subframe (like my car) or on the steering rack.
So I reckon you're right. It looks like the new recon rack has been machined and tapped to a non Citroen size. I'm now going to have to pull the pipes and take them along to show the supplier. The main pipe is nearly three foot long which is another job I didn't need on an already long list of stuff to do.  :(
Anyone happen to know the contact number of Citroen specialist Pleides in Sawtry?

Doc

DocBrown:
Just found out - and I'm annoyed at myself for missing this - apparently there are two union nut female extension parts that I should have removed from my old rack before handing it in. The new rack doesn't come with these parts and as you've already probably guessed they're not available separately. So now I've had to contact Remy Delco UK and see if they have tracked down my old rack and/or can source the two vitally important parts needed so I can plumb in the new rack. (I'm hoping that since there can't be that many Xantia steering racks floating about now since the scrappage scheme, maybe I'll strike lucky and they'll find it), I found this out after contacting Citroen specialist Seven Stars Garage in Sawtry, Cambs. The very helpful bloke on the end of the phone said I'm not the first or last person to forget these parts as they appear to be part of the rack....
So I'm now preparing the guest room for Mister Cockup while I hope that either Delco can get the parts...  :-[

Doc

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