Help 1.9 87 D Engine Needs Attention Or Replacing

[GTIJulian 0]

My 1987 D reg 1.9 205GTI needs attention. It’s done 110K. My dad got the car when it was a year old and has spent time in the past lowering it by ½ inch, fitting a 3 into 1 exhaust manifold and cupronickel brake pipes through out, so is a known devil and worth preserving! I have looked after it. He gave it to me when I became a dad and two seats were no longer enough! (MK1 MR2).

 

I've spent some time reading through various posts and it would appear that a complete engine replacement might be my best bet if I can find one. I've seen a couple on ebay but they don't come with ANY guarantee! I guess I could get such an engine rebuilt and tested though. I am willing to get mine repaired if it is feasible but would have to put it into a garage or find someone who could help out substantially in my area or within reasonable driving distance (I’d like to get involved to learn, and possibly reduce cost). My classic car insurance comes with breakdown cover!

 

I have done quite a few jobs on the car including:- replacing the timing belt, handbrake cable, alternator, starter motor, Oil(!), coolant(!), tapping three holes into the rear beam into which I screwed grease nipples (once pumped FULL of grease the squeaking stopped! – grease is seen to escape through worn seals!), universal joint gator (with help), brake hose, and two brake callipers…etc. BUT I don’t feel confident to do a big head off/engine out job in the street, or even in my dads well equipped garage with his help due to all the eventualities and hurdles which are bound to happen with such on old engine (stuck head/manifold bolts and lack of experience etc). I don’t really have the time to wait while parts, tools and the head is in the post. The head has never been off! So is likely to need welding to fill corrosion pits (have been skimping on antifreeze just lately as I think it may lessen the effectiveness of the Radweld), skimming, and reconditioning…

 

Summary of symptoms:-

1. Crack in the engine water jacket block just above where the dip stick enters the engine which is about 4 inches long in total (it spans a contour in the block where a bolt is). I estimate the difference in crack edge alignment (not gap) to be 1-2mm. Radweld has reduced the coolant leak to a manageable drip – I’ve tried putting a chemical metal patch on but it was hard to remove ALL (even though I drained coolant ) water and dirt/oil after polishing with a dermal…. I’m not convinced welding is a good long term solution, but am not ruling it out.

 

2. The slow evolution of general symptoms is pointing just recently to a H/G leak also! :- Firstly overheating (not enough coolant), I replaced a leaky water hose in the process, then cheese, now your actual steam!

There has been more than the usual amount of ‘cheese’ in the filler cap – although the car does lots of short journeys (I think the boy should walk to school so I can take the car to work!). I have been regularly topping the coolant up but it boiled recently, the steam coming from under the distributor cap, and I now notice a liberal spattering of Radweld below it – not good… Thought it might be the thermostat seal, but no, it is below this and concentrated below the distributor cap.. The thermostat passed the hot water open/closed test.

 

3. Noisy tappets (I know, a feature but probably need shimming after 110K)

 

4. general leaky oil seals and some stiff water/oil pipes..

 

5. squeaky water pump bearing

 

6. The clutch still seems fine but I think I’m running out of (replaced) cable adjustment.

 

If the head and engine have to come out then it makes sense to replace some parts and upgrade others in the process – engine mounts for eg.- will take advice.. An engine replacement could negate this of course..

Sorry this has turned into a life story… In short does anyone know a mechanic experienced in advanced engine work on 205’s and trustworthy too, in the W London area, or failing that not too far away… (GSF/Peugeot(expensive) are a couple of miles away)

Does anyone have a 1.9 87 – 89 engine?? I would really like to get the Pug back on form…HELP!

 

Cheers

GTIJulian

[dcc 855]

I think you have a tired block. they do rot after time, I had an mi16 block which sounds like it was in similar condition to yours.

 

Personally I would source a new engine to rebuild or an already rebuilt one...

[Miles 331 1 Cars]

Difficult one this as keeping the old engine would have been better but with it being cracked buts the end to that.

On a good note any 1.9 GTi engine will fit from a 205 or 309, Just the odd sensor maybe different but it's a case of just swaping them over from engine to engine.

 

Not that many good 1.9's out there, Same old reason now 'AGE' so a rebuild is a good idea if your going to keep it for another 20 years +

[MrG 3]

I agree with Miles, find another 1.9 and have that rebuilt. Or at least a new block. They're not expensive to buy if a good one is found though.

[GTIJulian 0]

Thanks for your suggestions guys......

 

Anyone know of a mechanic or preferably a small garage within 100 miles of West London with 205GTi experience who could do the engine and other work for me?? Or if highly recommended almost anywhere! I get the impression that the labour charges should get less the further you go from London!

 

Cheers

GTIJulian

[peakrevs 0]

Thanks for your suggestions guys......

 

Anyone know of a mechanic or preferably a small garage within 100 miles of West London with 205GTi experience who could do the engine and other work for me?? Or if highly recommended almost anywhere! I get the impression that the labour charges should get less the further you go from London!

 

Cheers

GTIJulian

 

Shenpar know what they're doing.

[chrisj21 2]

Miles or Dan taylor (talorspug on here) are both highly recommended on the forum.

 

You sound like your fairly confident with mechanics so you may find a rebuild easier than you think. Theres plenty of knowledge on the forum regarding rebuilds etc.

 

Good luck and i hope you get it sorted.

[MrG 3]

for the cost of a low loader taking your car off to a known and respected forum member has to be a good idea rather than finding someone nearer to home only to have issues.

[sub205 5]

i recently upgraded my 1.9 to a 2.0 with the newer engine management.

fuel economy raised from 10l/100km to 8l/100km and with a better camshaft and some headwork, my engine puts out 157bhp @ 6000rpm, not bad for an 8v.

so if replacing the engine, maybe this is an option for you too ?

the 2.0 engines mostly are in far better condition as the 1.9 ones and are widely available.

 

engine rebuild is no rocket science. its just important to know the basics and follow some important rules, the rest is just plain mechanics as everything in a car.

Edited January 11, 2010 by sub205