[engine_work] 205 Gti 1.9 Miami Blue

[BlueBolt 156]

OK...

 

So I saw this car on feeBay and decided that I really wanted it!!

 

(Not the original picture from the advert!!

 

I drove from Walderslade Kent, to Co.Durham to get there nice and early and miss all the traffic!! Which worked well!! Got there for about 10am...

Nice easy slow drive back home, total of a 12hr round trip, not too bad with my pregnant mrs driving the Leon all the way back... Didn't do too bad

 

So, after a night out, and then being given permission to wash her up etc she comes out like this::

 

 

 

 

 

 

So... She came with::

 

"K&N open filter" - That translated to k&n adaptor with some cheap worn out open filter that would probably benefit from being washed with the rubbish at the dump, let alone anything else!! lol

 

"Part service history" - This meant that they had a couple of previous MOT's, a little bit of work done receipts that got it through them, and a rr print out from 2007, and a receipt for a sound system that was once installed and has been removed since...

 

"Full years MOT" - The more I do to the car the more I find that this was obviously a mickey mouse MOT...

 

So, I look round her, and see that there are a few things that need to be done...

There's a switch in the drivers glove box, I assume it's for the cooling fan as I'd fitted one to my 1.6 previously. Look into it and see that they've put the wiring through, put a switch on one end and not done anything on the engine end of the wire other than coil the wire up and tuck it away somewhere. 5 mins pissing around with the wiring, finding it and attaching it to the tester connections I have a switch inside the car that operates the fast speed fan...

 

 

Then, to my surprise, a week later I found out that the fans were working perfectly fine on their own!! Why had i bothered to mess about with them, and why had the previous owner gone through the hassle of fitting the wire through???

 

So... I decided that while I was out there I'd get the strut brace fitted::

 

 

So, mod' 1 and fix 1 have been added, time for some more cleaning, claying, waxing... I'm not going to keep posting up pics of that though as it'd just be pic after pic of me having cleaned and waxed the car up...

 

So.....

 

I was then looking through ebay and found a nice new head that I wanted!!

Well, new to me at least!!

 

The specs of this were::

 

"Built by Puma Racing (Dave Baker)

Fully ported

New inlet and exhaust valve seats

New 42.5mm inlet valves

Piper cam P16BP300 2800-7500 range duration inl 304deg exh 34 deg

Inlet and exhaust lift 12.9mm (supplied by Brett sims)

New double valve springs

New valve guides

new seals throughout

Head comp ratio 11:1"

 

So, with a little insurance claim on it's way to me, I thought I'd spend a load of money and buy it

 

Before fitting, I obviously needed to get all the belts, bolts and bits to go with it, along with new (to me) shocks and springs as the drivers side shock had gone, hence the reason for the drop on one side on the first picture...

 

(More to be completed once I get back home...)

[allye 530 3 Cars]

you've got a rare spoiler on that! if it says gutmann on it its even rarer! good luck with it, looks like a good clean car.

[BlueBolt 156]

you've got a rare spoiler on that! if it says gutmann on it its even rarer! good luck with it, looks like a good clean car.

 

 

Yes mate it does, didn't realise it was a rare one, but I haven't seen many about... And intend on keeping it

 

Thanks

[BlueBolt 156]

So in the middle of all the head work, due to having to wait for new drop link bars from feeBay, the old came off, and the new-to-me went back on... This lot with poly top bushes on the shocks::

 

Reason for the change:

 

New bits in::

 

As with everything though, it would appear that nothing wanted to go to plan with this but, the big bolt that clamps the hub around the shock on the drivers side decided that it didn't want to come undone... Instead it wanted to snap like this::

 

So with a little persuasion in the name of a short handled mallet, and a new bolt off my 406 Coupé hub it came off and was replaced too... Not without a few badly aimed clumps with the mallet and a LOT of abusive language aimed at my "flipping French heap of lovely car"... Maybe not the exact words used though lol

 

 

 

 

So, before the big works begin, and bring me to the place what I'm at now then she looks like this::

 

(Please excuse my constant use of the phone camera, some pics come out great, others not so great lol)

 

The the work begins!!

New head going on goes something along the lines of this::

 

Some bits off

 

Leaving gaps:

 

And oh so glad I don't need to clean this side up:

 

Then comes the first problem::

 

Bottom pulley DID NOT want to come undone!! I know they have to be done up tight, but seriously, this took the mick!!! So we left it for the night and came back to it the next day!!

 

The next day, fresh from another night out, and with my two eldest boys running around us playing and 1 (youngest) wanting to constantly know what we were doing (Good thing as far as I'm concerned as it shows the Petrol Head potential lol).

Got the bottom pulley off, cam belt off and head off... Good thing I went down this route as it looked like it was going to need doing soon in any case::

 

 

 

Then for the new bits.....

 

 

 

Water pump off... New one in...

 

 

Old on the left, new on the right::

 

 

We tried to line it all up as best as poss, with the theory that we would get the timing better once the head was on, making sure everything was clear, no valves hitting pistons, nothing in the wrong place, everything as it should be...

 

First though, everything needed cleaning up and making tidy::

 

Gaskets in place

 

And finally, after 6 on and off days, admittedly a lot more off than on, and during a work week, the head new head goes on::

 

The bolts go in...

 

And slowly but surely get tightened up...

Having not done a head-gasket, or anything like this before, it's always nice to have heard lots of horror stories about threads stripping, bolts skipping threads, and several other stories before this happens!! Cheers mates!! lol

 

 

So, now it's all in, the tensioner, belts, rocker cover, and obviously, new exhaust manifold has to go in with the full stainless system now sitting under the car eagerly awaiting it::

 

 

 

This brings me nearly to the end of what I've done so far... Obviously I have completed the putting the engine back together, inlet on, filters on, pipes and wires connected to the places they should be (as far as I can gather anyway??)

As mentioned in the first part, I'm now stuck at this point which is doing my head in!! So if anyone has any ideas for me, or lives local enough to come and have a look and show me something blindingly obviously that I've got wrong...??? lol

 

I've got a few more bits done, but if I don't put the laptop down soon the mrs will kill me, by stuffing dirty nappies down my throat as I'm neglecting her and my 10 day old baby apparently lol

 

There are lots of plans, and they will be completed bit by bit, now that I have my GTI I intend on keeping her and building her into something different from anything I've done before...

 

p.s. The parts taken off the 406 Coupé were easy to do so without problem as I am stripping it to pieces!! 3.0l v6 engine in it with 63,500m on if anyone else is wanting to do that MAD project lol

[Daviewonder 533 3 Cars]

Nice looking 205. Are you aware it's a limited edition on a G reg in Miami blue? (only 150 made in 1.9 and 150 in 1.6). Does it still have the full leather interior fitted?

Edited September 7, 2011 by Daviewonder

[BlueBolt 156]

Nice looking 205. Are you aware it's a limited edition on a G reg in Miami blue? (only 150 made in 1.9 and 150 in 1.6). Does it still have the full leather interior fitted?

 

 

Yes mate, made a complete steal of a purchase when I got it... Knew it was the limited edition, still got the grey leather, in good con, still got the grey carpets too.

Is there a way of finding out what number of the ltd i got??

 

I always thought it was 300 in 1.6 and 300 in 1.9...??

[jackherer 543]

I always thought it was 300 in 1.6 and 300 in 1.9...??

 

Thats right, and the same again in Sorrento for a total of 1200.

 

They weren't individually numbered.

 

It should have orange front indicators.

[Daviewonder 533 3 Cars]

Thats right, and the same again in Sorrento for a total of 1200.

 

I thought this at first too but was repeatedly told 150 of each by various forum members?

[BlueBolt 156]

I thought this at first too but was repeatedly told 150 of each by various forum members?

 

 

 

:rolleyes:

Makes it even better then lol

[james_pug 26 1 Cars]

Chris isn't it? I bought some hubs off you a few months ago, good to see your still working on it, sorted the problem with the head out yet?

[BlueBolt 156]

Chris isn't it? I bought some hubs off you a few months ago, good to see your still working on it, sorted the problem with the head out yet?

 

Yes mate, that's me!!

Thought it was you from the friend req'...

 

Not got the head sorted yet, am leaving it till weekend after next when I'm going back to point one and starting the complete timing thing all over again!! gotta do some research between now and then about timing up the Piper cam and where it should be placed etc...

 

How you getting on with yours??

[BlueBolt 156]

Right, so I thought while I've got a minute or two I'd add into the thread about the other bit's I've done so far to add into the car......

 

First off was the twin fans::

 

 

Bought off feeBay and installed whilst on a fag break at work.

Only got the one fan running at the moment, but as this was how it was with a single fan, I'll play with the wiring and get it running both sooner or later......

 

 

 

 

 

 

The plans for what needs and wants to be done have grown!!

 

I've been reading a lot of threads on here about general works to be carried out, things to do to the car to keep her from rotting, and things that will help with the rust, lack of rust, and cure of rust and so on and so forth!!

So my plans are::

 

Get the car running!!! Would be good start I guess??

Sort out the heating... Or lack of it!! (Thanks to james_pug for the control box)

Sort out the wiring to the twin fan

Get all the bits to complete driveshaft and lower arm change.

I'll be getting the 309 wishbones, got some new (to me) drive shafts to replace my current one's. Will replace all bushes on wishbones before fitting.

Change brakes

Thanks to hcmini1989 for the 4pots. They'll be going on. Just need to get myself a different master cylinder to run them with more effect

Fit blue hose kit to engine bay, also thanks to hcmini1989 for these.

Look out for gutmann wheel arches so as to keep the tyre tread covered and not have the wheels too far out.

 

 

That will cover the parts that I have, and will get me to the starting point for collecting the next lot of bits for it....::

Buy some under body sealant

Along with brake pipe and new fuel lines

Get my brother to clear his garage out and get my car in there to get in the air, get the underneath cleaned and prepped and sorted so I can paint/preserve it.

Replace all brake lines and fuel lines at the same time, thinking about upgrade the fuel pump, fit different fuel pipes and generally give the underneath an overhaul (it is 21 yrs old and probably needs it by now after all.....)

 

 

This is by far only the start of the list of things to complete, but as I intend to start these works over the coming weeks (as I am now not starting work till 3pm I should have some daylight hours to be able to do so).

I'll make sure I keep it documented and update this thread as things come along...!!

[Baz 421]

Nice little project!

 

Cam spec sounds like a the old Piper A/2, same as in my Longman engine, i have the timing setups somewhere, but it should also be easy to find online i suspect.

[BlueBolt 156]

Nice little project!

 

Cam spec sounds like a the old Piper A/2, same as in my Longman engine, i have the timing setups somewhere, but it should also be easy to find online i suspect.

 

Thanks, I love her lots, but right now I'm loving to hate her!!

 

Timing setups would be very useful if you have them... saves me searching as I'm a bit harder for time than I thought I would be this weekend...

[ellis 7]

great work fella, nice clean looking car

[BlueBolt 156]

Nice little project!

 

Cam spec sounds like a the old Piper A/2, same as in my Longman engine, i have the timing setups somewhere, but it should also be easy to find online i suspect.

 

How did you get on finding them timing up bits mate?? Got to get playing with it this weekend coming, be good if I had a place to start with... Not found much on the Piper site about it to help me out as yet either

[MiniGibbo 142]

Nice car, imo the greatest colour for a GTI even nicer than white

[BlueBolt 156]

Nice car, imo the greatest colour for a GTI even nicer than white

 

Cheers man!! I love it!!

 

Do like some of the other colours, but this is my second Miami and i'm happy to stick with it for the next one... which there will no doubt be!! lol

[BlueBolt 156]

So....

 

Been a while since I got anything added to this thread so I thought it was about time I put some more effort into the build/works thread...

 

Having had somewhat of an epic fail with the head, I had a few conversations with Miles and came to the decision that I would send it down to him to add an Omex600 system to it, and get him to time it all up and get it going for me, and tinker it a little bit...]

Then the conversation progressed a little bit, and the plans changed a LOT!!

 

The head came off the engine and got sold::

 

 

Then, as the car is to be having a new engine put in (part 1 of the plan), I have taken the engine out too...

 

 

 

This was a few weeks back now. I have since then been quite busy!!

 

I have put some effort into rebuilding the gti6 calipers that I bought for it. I got a lot of the information I needed from this thread and as such have managed to get a good finish on them, not painted, but cleaned up... Haven't got the time to paint them up and get them all spangly but got a good clean finish, all the old paint off, new seals in and put back together...

Getting the pistons out of them wasn't the easiest of things to do, but with the advice of the thread I linked already, I managed to do it::

 

 

 

And with a few pump pump pump's, this was the result::

 

 

 

Thankfully the pistons were free from corrosion and I didn't need to replace them. Was going to struggle if I had needed to I think!!

The calipers are now cleaned, sealed and ready to go back on.

New bleed nipples fresh from Pug were a rather expensive choice that I did not need to do, having looked at the old one's, but I wanted to have new covers for them so thought I would just replace them::

 

 

So, with my nice new braided lines on, new discs in the box ready to go on, and a set of Mintex 1144's on their way to me as of today, they are ready to go on the car later this week.

 

The next thing to do is to refurbish the rear calipers. I'll be taking them off the car tomorrow I think and taking them into work to clean up in my lunch break. Sure the boss will be well happy about that lol

 

 

Other bits that I have managed to get done are stripping the whole dash out!! This thread helped me with this job, and thanks to some help shows the downloads for the diagrams that helped me take the whole lot out.

 

 

This wasn't for the purpose of stripping the car out, it was for the reasons of replacing the heater control unit. Old one out and new one in, I waited till I had got the control unit back in and then decided that I wanted to replace the matrix... Work stopped for a few days while ECP managed to balls up my order, not get it to the shop, and end up delivering it to my flat (even though they don't do deliveries to domestic locations!!)

Edited March 5, 2012 by BlueBolt

[BlueBolt 156]

So, back to the plans for the car...

 

The 1.9 lump is coming out of it. The head has already been sold, and a 2.0 GTI6 lump is taking its place, courtesy of the craftsmanship of Miles!!

To give me a little bit of an edge, the lump is getting fitted with a set of Jenvies, Omex600 ECU, and a few other goodies along the way.

 

I'd love to be building it and completing the work myself!! But as I have learnt already, I do not have the knowledge, time, space or workshop to be able to allow this. I am therefore quite glad that I have come to know of PugRacing and Miles. The car will be going to him within a week and having the works started!!

 

As I have mentioned, I am replacing and refurbishing all the brakes, adding the braided lines into the scene, front and rear. This is the main thing I need to get completed this week before I take it down.

Besides this, I need to finish putting the dash back together, matrix in and so on. Remove the drive shafts that are being replaced. Clean the insides out and get all the odd nuts bolts bits and bobs out, clean it, and get it hoovered out!!

This should be do'able once the brakes are sorted as I'll push her over to near the door to my car park and bring the hoover down to the car finally after a long time!!

 

Whilst the brake lines are getting replaced I have ordered myself a new master cylinder, this enables me to not be too worried about how much of the brake fluid I loose whilst replacing the lines when I'm sorting the calipers, also letting me make sure that there is a complete new and fresh set of brake fluid in the lines throughout...

 

I'll get more pics up and more info at the weekend when the car goes away and is sitting on the back of a transporter.......

[samthornton1990 23]

Looks worse than my d turbo behind the dash! Good project man!

[Daviewonder 533 3 Cars]

Sounds like it's gonna be pretty awesome when it's done. That dash picture scares me quite a lot as I need to replace the dash on mine

[BlueBolt 156]

Haha

 

Don't be scared or put off by the pics of the dash... I left half the connectors on the fuse-box side as I didn't need to get the whole thing out of the car, as long as I'm clever while I'm putting it all back in together then it shouldn't be much hassle, it's been placed back at the moment, waiting for the matrix to go in and a few other bits this week too...

 

Thanks for the comments

[gsidave 3]

Don't worry chris my red gti will find a good home for that 1.9 lump.

Looks scary with the dash board out don't they. Looks like a nice condition gti in blue.

[BlueBolt 156]

Glad to hear it will get good use!! Was good running order till I got my tool box out and pissed about with the head change...

 

Yea, it's actually a nice condition shell, bit of decay in the engine bay, but I'll get to that later in the year when I've had some time with it running lol