Citroen Xsara Picasso 1.6 HDi - allen key fell in clutch housing: Help please!!

Honest John Back Room » Technical matters
View Threaded
Sun 11 Jul 2010 14:11
Citroen Xsara Picasso 1.6 HDi - allen key fell in clutch housing: Help please!! - grayman

Hey guys - please help! ... particularily from gearbox/clutch knowledge/ mechanics/specialists/ for 1.6 HDi (I believe 2.0 HDi- engine is quite different?)

I was attempting the difficult screw on the end of the 1.6 HDi air filter case (year 2004) when the 4mm Allen key fell into the inspection hole (or whatever function) at the top of the clutch housing, almost directly below... the key is not in sight.

At present I see no way to get it out without dismantling by a garage for a 'clutch change' - and it would need transporting as I am scared to run the engine in case it jams the allen key...

Ok - any other solutions/good ideas?

I have taken off the under-engine pan - nothing useful seen except am horrified by how small is the clearance between flywheel teeth and the casing - bang goes my hope that maybe I could either forget about it, or find clearance to fish it out... No way. (and 'bang' would, I think, be the result if I started up the engine...)

One crazy idea: if this is just 'air space' inside the casing at the lowest point- could I drill a large enough hole in the alloy to fish for it? (I know - ridiculous. just desperate...)

1) Can anyone advise serious, more do-able possibilities? Mechanics/specialists: - it must have happened to someone else at some time... (but I guess you charged owner for a new clutch... ??!!)

2) What is expected clutch life on this diesel? (Car has 62,000 miles and clutch SEEMS fine...).
Is there any way to check/test clutch remaining life/wear without dismantling?
(If clutch really 'about to go', then this is perhaps the answer).

3) Can anyone point to - or forward - an exploded diagram/ workshop manual/ whatever/ of these components? I googled all I could imagine - have found nothing for Xsara Picasso 1.6 HDi (only 2.0 HDi) - or is there a same/similar engine/gearbox layout in another car that I might find diagram?

Ok - hoping for your help ASAP...(!) My car is immobilised until a solution is found! :-(
Many thanks...!!

Edited by grayman on 11/07/2010 at 14:14

Reply | Report as offensive | Link
Sun 11 Jul 2010 15:33
Citroen Xsara Picasso 1.6 HDi - allen key fell in clutch housing: Help please!! - Avant

Is it possible to find a strong magnet of a suitable shape to insert into the housing?

Reply | Report as offensive | Link
Sun 11 Jul 2010 15:52
Citroen Xsara Picasso 1.6 HDi - allen key fell in clutch housing: Help please!! - V4 Heaven

I have a telescopic pen like device with a small (less than a 5p piece size) magnet on the end; bought it from a cheap market stall but I'm sure one will be for sale in Halfords. It's helped me out in many situations and has prevented similar expensive stripdowns. Good luck!

Reply | Report as offensive | Link
Sun 11 Jul 2010 16:05
Citroen Xsara Picasso 1.6 HDi - allen key fell in clutch housing: Help please!! - grayman

Hi V4 Heaven / Avant -

one problem is access - it is so awkward to get to! -
On Monday I shall have to treck around possible places looking for some kind of magnet - I tried imagining some 'sticky' solution, but so far magnet seems preferable: anything 'sticky' also seems risky to drop off/stick to the wrong things... Problem is - it will have to go around inside the case - so 'magnet' may need to be a bit special...

The 'telescopic magnetic probe' is too rigid - as I said I would need something to go around corners - as yet I have not turned the engine at all though am considering jacking up the front wheel and in 5th trying a slow turn of a few degrees at a time... - but I don't know if ithe allen key bounced forwards or backwards - so maybe it is balancing somewhere out of sight, ready to drop further if I go the wrong way...!

Now if I had a nice fibreoptic flexible, dirigible camera, with lightsource and a little grabber, like they use in operations... - well, any surgeons out there want to lend me one? (I'd wipe it well afterwards... promise! ;-))

grayman

Reply | Report as offensive | Link
Sun 11 Jul 2010 16:37
Citroen Xsara Picasso 1.6 HDi - allen key fell in clutch housing: Help please!! - grayman

Added info/request re battery connection:
I have just been poking around again under the bonnet - I see I can create more access to the 'inspection hole' if I unbolt/move some things - (electrical... plus a large plastic attachment plate above the suspension) -

Question: If I disconnect the battery for safety (a major +ve terminal is on this plate, eg for jumper-lead access...) -
on these cars, what if anything do I have to re-set after? -
or does the inboard computer etc remember all its settings etc?
(Sorry - not done this before - my last car had none of the computer stuff...!)

Early reply VERY much appreciated...
grayman

Reply | Report as offensive | Link
Sun 11 Jul 2010 17:02
Citroen Xsara Picasso 1.6 HDi - allen key fell in clutch housing: Help please!! - Peter D

Removing the statrter may give you the access you need. Worth a look. Regards Peter

Reply | Report as offensive | Link
Sun 11 Jul 2010 19:24
Citroen Xsara Picasso 1.6 HDi - allen key fell in clutch housing: Help please!! - madf

Personally I would run it and hope the allen key breaks up...

Reply | Report as offensive | Link
Sun 11 Jul 2010 20:13
Citroen Xsara Picasso 1.6 HDi - allen key fell in clutch housing: Help please!! - Peter.N.

I to would be inclined to start it up and see what happens, it could very well have fallen safe. If it will turn over on the starter it should be OK, the teeth on the gear ring are pretty hard. The only other suggestion is to slacken off the engine-gearbox bolts and see if you can create a big enough gap.

Reply | Report as offensive | Link
Sun 11 Jul 2010 22:39
Citroen Xsara Picasso 1.6 HDi - allen key fell in clutch housing: Help please!! - grayman

Hi all -

I normally don't like to admit I was wrong - but... this time I am delighted!

I have the allen key back - and confess that with very bright sunlight and eyes not as sharp as they were - what I thought was a hole was a recess... since dismantling to get better access, I have retrieved the key - hidden out of sight - to my very great relief!

Many thanks to those that replied, for your ideas and your time. --
Unfortunately I cannot edit out / remove the post... :-D

Happy driving...

Reply | Report as offensive | Link
Mon 12 Jul 2010 10:10
Citroen Xsara Picasso 1.6 HDi - allen key fell in clutch housing: Help please!! - madf

Pleased to here it's sorted..

(I told you to just run it :-))))

Reply | Report as offensive | Link
Mon 12 Jul 2010 11:45
Citroen Xsara Picasso 1.6 HDi - allen key fell in clutch housing: Help please!! - Peter.N.

I bet that was a relief!

Reply | Report as offensive | Link