[engine_work] 1990 205 1.9 Restoration And Upgrade.

[chrisj21 2]

Chris, is it finnished yet?

 

 

Affraid not Mark, Daz the slacker let me down on Saturday

 

Although with some of the quotes i've been getting today for insurance it looks as though it will be on it's way to a new owner when it's finished

 

Hoping to put a few hours in this evening, get the head on and timmed up.

[Tesstuff 222]

Affraid not Mark, Daz the slacker let me down on Saturday

 

Although with some of the quotes i've been getting today for insurance it looks as though it will be on it's way to a new owner when it's finished

 

Hoping to put a few hours in this evening, get the head on and timmed up.

 

You lying little sh1t

[chrisj21 2]

All i remember is some text message saying you had only just got signal or some excuse and you couldn't make it.

[Tesstuff 222]

Selective memory there Chris?

 

I remember a text from you THREE HOURS before mine saying you were really busy at work and probably wouldn't be working on the car today

 

Buffooon

[chrisj21 2]

You'll be pleased to know i've saved the fuel rail bolts and injector clips for you Daz, wouldn't want to spoil your glory

 

I'm hoping to have it running by the 7th March now, the list of jobs is as follows.

 

Remove the stuburn top engine mount from the body and install new mount.

Get new bottom mount pressed in to yoke

Get new bottom fork bush pressed in

Fit new bottom pulley to engine

fit head gasket

Fit head to engine and time up

Fit starter and alternator

Swap the vts diff for the 205 one

Fit clutch, gearbox and new driveshaft oil seals

fit non pas rack

Attach the inlet and exhaust manifolds

Get engine fitted in place

Fit various clips, light wiring etc

Fit the wiring and wire up the engine.

Mount the ecu

Fit driveshafts, hubs and brakes back on

 

 

The list is more for my own use really, i'll mark things off as i go along.

 

Quite a list really so i better get cracking.

[marksorrento205 80]

Is there a reason why you are ditching the pas? The gti6 pas pump and pipework set up is so easy to plumb in. I have a pressure and return pipe to suit if you decide to keep it. I will pm you later about pressing the mounts in as I have a press

[chrisj21 2]

My racks had it to be honest Mark, i got a cheap enough non pas rack from simes on here and i miss my old 1.6 with non pas so i'll give it ago. I also plan to fit a west midlands motorsport quick rack in the near future.

 

Indeed you have i forgot about that, I'll await your pm

 

I'm after a 309 beam tube if you come across one or know of one?

[marksorrento205 80]

I will send a pm in the morning when im at work How bad is the insurance quote? I only know of one 309 tube at the min but its spoken for. Jord294 may have one. He is mr 309

[chrisj21 2]

Bad enough, i'd set myself a budget and it far exceeds it.

 

I don't think Sophie will be too pleased and we're just looking at getting a new scirroco or another mini but the john cooper s works r56 model so thats going to enough as it is what with 26k price tag.

 

It may just become a weekend toy but we will see. Who are you insured with Mark if you don't mind me asking?

[marksorrento205 80]

Direct line all mods declared

[chrisj21 2]

Remove the stuburn top engine mount from the body and install new mount.

Get new bottom mount pressed in to yoke

Get new bottom fork bush pressed in

Fit new bottom pulley to engine

fit head gasket

Fit head to engine and time up

Fit starter and alternator

Swap the vts diff for the 205 one – Half done, just need to seal up the diff houseing

Fit clutch, gearbox and new driveshaft oil seals

fit non pas rack

Attach the inlet and exhaust manifolds

Get engine fitted in place

Fit various clips, light wiring etc

Fit the wiring and wire up the engine.

Mount the ecu

Fit driveshafts, hubs and brakes back on

 

 

Getting there! slowly.

 

Managed to time the engine up after two attempts, turns out the original dampered pulley was out a touch, fitted miles' bottom pulley and all was fine. I'm slightly unsure as to whether i've tensioned it to tight so i'll have another look at that tonight, i can just about twist the belt with my fingers 90degrees.

 

I had planned to get the clutch on but lost my alignment tool so i'll pick a new one up this week.

 

Any recomendations as to what to seal the diff housing with?

Edited March 1, 2010 by chrisj21

[chrisj21 2]

Remove the stuburn top engine mount from the body and install new mount.

Get new bottom mount pressed in to yoke

Get new bottom fork bush pressed in

Fit new bottom pulley to engine

fit head gasket

Fit head to engine and time up

Fit starter and alternator

Swap the vts diff for the 205 one – Half done, just need to seal up the diff houseing

Fit clutch, gearbox and new driveshaft oil seals

fit non pas rack

Attach the inlet and exhaust manifolds Exhaust manifold has been cut and will be welded this week.

Get engine fitted in place -Just waiting for the above

Fit various clips, light wiring etc

Fit the wiring and wire up the engine.

Mount the ecu

Fit driveshafts, hubs and brakes back on

 

Nearly there now.

 

I've loads of pictures and info to write up which i'll do tomorrow, hopefully someone will be able to make use of it in the future, or not.Gearbox was a bit of a pain but went on with the second attempt, couldn't quite get the fork in the right position the first time.

 

More to follow.

Edited March 7, 2010 by chrisj21

[twoker1986 0]

glwtp

[chrisj21 2]

Update time.

 

With the engine basically re assembled and ready to drop in i've been working on removing any rust from the engine bay and getting ready for paint.

 

I'm not looking for a concourse finish here, just something to last well for a few years until a full car respray is in the cards.

 

I've done about 8 hours now and removed all the rust using the wire brush and drill, sanded down any minor bits and primed. I slowly worked my way around making sure all the rust is removed, de greased and sanded.

 

Rust removal from the inner wing

 

 

 

Primed first with red oxide

 

 

opposite side

 

 

With the inner wings primed i moved to the outer slam panel areas

 

 

 

Then down the chassis rails.

 

 

Then primed the whole area with zinc primer

 

 

The opposite side has also been done and the strut tops and bulkhead rubbed down ready for primer.

 

Finish priming tomorrow and then paint on Monday.

Edited May 29, 2010 by chrisj21

[chrisj21 2]

All painted !!

 

And looks really good, really impressed with the results.

 

I'll let the pictures do the talking

 

 

 

 

So happy with the results, i put about 8-9 hours in on the preparation, sanded all by hand and removed a few bits of rust with the drill. I made a canopy to cover it and protect from the dust which worked really well.

 

Colour match is also much better than i expected.

 

Just need to clean everything else and put it back together.

[Daviewonder 533 3 Cars]

Looks like a good job , looking forward to seeing it all back together. I hope the servo will get a coat of paint before it goes back in

[chrisj21 2]

Funnily enough it's off and ready to paint

 

Everything will get a good clean and the engine a lick of paint too.

 

Thanks for your comments