[trackday_prep] Paul's Gti6

[Paul_13 212 1 Cars]

Hi all this is my first thread on here, I've got a Silver 1.6 GTI which had a 1.9 8v engine in it. Soon to be a GTI6 engine on a 1.6 box

 

I've done quite a few mods such as 309 running gear, big brakes and MC, roll cage, Spax suspension, seats etc...

 

The reason I took the engine out is because i thought the headgasket had gone, once stripped there didnt seem to be any damage. You can still see all the honing marks in the liners.

 

I did replace my fuel pump recently which fixed the nonstarting and cutting-out when cornering problems.

The AFM was also dodgy and combined with a sh*t earth caused the running problems.

 

I recently stripped out the engine and in the process of cleaning everything up here's a few pics:

 

 

 

 

 

 

 

New MC and brake lines

 

Look at the size of 'em!

 

 

Battery in boot

Edited March 30, 2009 by paul_xiii

[Paul_13 212 1 Cars]

Does any one know what the black sphere is for?

 

 

Theres a circuit board attached to it on the inside

[platty 1]

Hmm, looks like an infrared receiver for central locking to me.

[Baz 421]

It is!

[Paul_13 212 1 Cars]

hmmm...... wonder who's lost the blipper.

 

Should be alright taking it out? I remember that my last one didn't have it.

 

Baz- cheers for the door colour's pretty much a perfect match, we had a bit of fun grinding off the rust on the bottom.

 

I was on the way back Saturday and there was a Sierra Cossie RS500 that had just been sandwhiched by two lorries, owner was by the side of the road booing his eyes out... rightly so

Edited March 31, 2009 by paul_xiii

[Paul_13 212 1 Cars]

Did a bit more work at the weekend, mainly stripped the dash out and gave a few things a clean.

 

Few piccies

 

 

 

Small bits of rust here and there, could be worse.

 

Engine this weekend hopefully

 

Any body a clue of my problem?:

 

I'm getting a GTI6 engine and using the 1.6 box. I want to put a diesel/1.9 16v crank in.

 

Now would any machining be needed for the rods to clear the pistons? I thought the extra travel of the crank may cause some problems. (I've done a few searches)

 

I'd probably be better putting this in XU engine category...

[Paul_13 212 1 Cars]

Working till 4am on the car the other day sorting things out.

 

Ordered loads of new bits; quick rack, various bushes, fuel pump and engine coming next weekend

 

Few piccy's

 

Stripped the dash out and ripped off the sound deadening (weighs a ton!)

 

 

Removed the sunroof and sliders under the intention of fitting a blanking plate

 

 

Dropped the subframe out and gave it a clean, going to paint a few bits first

 

 

Where i'm going to place my ecu... for the moment

 

 

Do I need to cut this lip out to be able to fit the manifold from the GTI-6?

 

 

And dash back in

 

 

 

 

Loads of new bits coming tomorrow cant wait

[Paul_13 212 1 Cars]

New bits through today!

 

 

Quick rack and a few other bits still to come through

[Paul_13 212 1 Cars]

Bit of prep work ready for some filler. Bonnet had about 3 layers of paint!

 

[Paul_13 212 1 Cars]

Got my engine last weekend!

 

About to replace timing belt kit and figuring how the f*cking loom goes on.

 

 

 

Exhaust off ready to be re-angled

 

 

What goes in this hole? Bit stumped...

Its on the back of the intake near the throttle body

 

[welshpug 1,661]

looks like where the idle valve goes, hard so say without seeing more of the surrounding area to give an indication of where it is.

[Paul_13 212 1 Cars]

Slowly things are coming together, just a few bit needed now.

Also lesson learnt with not wearing a mask when welding! F*cking painful sun burn when i woke up in the morning

 

There's a few plugs that i have no idea what they are for, i'm missing the crank sensor but have one on the way.

Sorry for the amount of pics but any help would be brilliant!

 

1. Start of with an easy one (hopefully)

 

 

2. Just need the name of the sensor as i need a new one

 

 

3. I believe one of these is for the fuel reset switch, whats the other one for?

 

 

4. What are the white plugs for? I guess ones the crank sensor

 

 

 

Welshpug- looks like the part of the oil breather setup when i looked at my mates gti6

Edited May 22, 2009 by paul_xiii

[Rob Turbo 3]

My moneys with welshpug, I was playing with a gti6 inlet manifold last week and the only thing I can remember bolting on near the throttle body is the idle valve, it will have a pipe going from the valve to the inlet pipe just before the throttle body.

 

I haven't wired a gti6 engine before, and haven't even seen a gti6 loom in the flesh (so to speak, seen one in the copper maybe more fitting??) so can't help with the plugs, but #2 looks like an oil level sensor, I can't see it being used in a 205 so I wouldn't worry about it.

[Paul_13 212 1 Cars]

Cheers Rob Turbo, i'll get of these ordered then. Does any one have a part number?

 

Do you know where the hose goes after the ICV? (taking into account the intake hose already mentioned)

I'm a bit stuck to where the breather pipes go!

 

Thanks

[taylorspug 7]

The hose for the ICV goes from the inlet pipe before the throttle body into the ICV, and thats it. The ICV is attached to the manifold so breathes through there.

 

As for the electrical plugs, i cant view the images as my computer doesnt like imageshack, but from the thumbnails:

 

1- Cant even see a thumbnail.

 

2- Oil level sensor. You wont need it so just chop the wiring off and leave it in, or find a suitable blanking plug.

 

3- Brown plug looks like its for the carbon cannister, in which case you wont need it. Other one does look very fuel switch-ish.

 

4- If one of those is a three pin sheilded cable then it will be for the crank sensor. The other one if its three pin could be the VSS (vehicle speed sensor). An ECU pinout diagram and a multimeter would tell you what all of these are in about 2 mins for sure. I certainly wouldnt just start chopping without belling everything through with a meter first.

[Paul_13 212 1 Cars]

Thanks for the tips taylorspug, picture number 1 did display when i first posted it then dissapeared...

It paired with the oil sensor thats on the sump, its the longer one of the two I was after.

 

What would the VSS sensor connect to or is this obselete with the 205?

[rubyna 4 1 Cars]

You will need a vss sensor off an s16,Citroen zx16v and a few other models used the same-1,its a 3pin but with the speedo

cable hole on top next to it. I only know as i had trouble getting hold of-1 for my conversion...

[Paul_13 212 1 Cars]

Do you have a pic of it by any chance Rubyna? I'm a bit confused to where it's located.

 

I'm using a 1.6 box will this still be needed?

[rubyna 4 1 Cars]

yes 1.6 or 1.9 box, i havnt got a pic of it. What are you confused to where its located, the actuall

vss on the s-16 etc?

[Paul_13 212 1 Cars]

The actual VSS sensor, only sensors I know of on the box are the reverse light, crank sensor and thats about it

[Paul_13 212 1 Cars]

Update: Done a bit of work yesterday, mainly put the rack back together with the quaife quickrack components and had a clear up. Mate's getting a bit pee'd off with my 3 engines, bonnet and door lying around which is bound for the scrappy.

 

Forgot how much of a PITA the gaitors were to get back on!

Everything in place. Couldn't believe how many turns lock to lock this thing is. I'm gonna have arms like the hulk trying to park!

 

New wheels bit dirty though, tires only done about 300miles and for £300 quid for the lot. Bargain!

Sitting like a 4x4 with no engine in.

 

My old oil cooler union, snapped off due to me not using a spanner on the bottom half.

Its the type with the cone on the inside not the outside, does any one have a oil cooler rad spare?

[taylorspug 7]

The VSS goes where the speedo cable locates, speedo cable plugs in the top, electrical connection on the base.

[Paul_13 212 1 Cars]

Is it a white plug (3pin) on the loom which plugs into the VSS?

I've sourced one off Baz, was a bit clearer when I saw it.

 

Also any pictures of your E30? One of my favourite cars apart from the Pug

Edited June 1, 2009 by paul_xiii

[mattbenselin 0]

I presume the VSS unit is found on the 306 (most others too?) and fits the standard GTI box as that is what is being used for this build? I have cruise control kit and it needs either a VSS signal or uses an oldskool magnet on the driveshaft and coil pickup for speed signal.

Cheers

[Paul_13 212 1 Cars]

Matt- The VSS sensor is found on the 306, Xsara VTS and BX16V I'm pretty sure. probably a few other models aswell.

Wouldn't mind cruise control on my Dturbo for my journeys to Leeds!

 

You bolt the VSS on to the gearbox and the speedo cable goes into that. I'll PM you a pic