205 Gti 1.6 1992 Restoration :)

[idoari 10]

Hi,

 

let me intreduce myself my name is Ido i live in Israel and after 1.5 years of searching (i Israel the GTI is quite rare) i bought a 1.6 GTI.

the car is looks like well maintain (it has a strong engine and good gearbox) but doesn't have service history. so i decided to do a complete restoration ( both mechanicly and cosmeticly).

the main isue with this car is the electrics. the electrics is very very dodgy (a love of broken and missing wires). luck for me i'm a electronics engenneir

 

​

 

as far as i know, the 1.6 engines has two codes : B6E and B6D but i have B6J engine and i can't find and info on that model (maybe late model engine ?! )

the engine code is engraved on the block and the injectors and the dizzy is differenct as well.

 

​

 

the engine number plate is removed

 

​

 

 

tomorrow i will upload more pictures and tell you what i've done til now.

 

Ido

 

 

[idoari 10]

sorry about the delay...anyway this is how i got the car

 

​

 

​

 

the instrument cluster

 

​

 

 

​

 

in my way back home i noticed that all of the gauges in the dash (water temp, oil presure and temp) are not working and also the car stoll in the middle of the road twice and didn't want to start. after two minute i manage to start it. from that moment i knew that the first thing to fix it the dodgy electrics.

 

in the first day i remove all the stickers from the car and remove the ugly floor mats.

 

all the sunroof trim was LOADED with silicone and so is the handle (probebly becasue of a leak)

 

​

 

 

i hate that exhaust !! it WAY too loud , i will change it later on...

 

​

 

the engine when i got the car . first thing i saw is the aftermarket filter that sitting on top of the exhaust manifold - i will get rid of it later on and get the original filter box with the hoses.

 

​

 

the second thing i saw is the loom wire was rubbing on the plastic part that connect the throtle cable to the throttle body and stop it from closing all the way. the ideal was troable also ( the RPM keeps climbing up and down from 2K to 1K). i saw also that one of the wire of the throttle switch is broken (the middle one) and the two other is partly damaged. also i removed the wire that holds the battery in place and i will replaced it with a proper battery clamp.

 

i remove the paddels coves that came with the car, paint them and install the genuine rubber cover that i bought

 

​

 

​

 

 

i bought with the car a set of original 1.6 rims that is going back to the car.

 

​

 

 

here's what i've got with the car (they are 15" rims)

 

​

 

i replace the steering wheel becuase the one that i have was way too worn ( i know it's grey steering wheel but i'll replace it to black one later on)

 

​

 

original gear know that i bought

 

​

 

i put back the original rear light units that i've had. the lens is broken on both sides so i've replace that to brand new on later.

 

​

 

in the meantime to pass the MOT i've had to have a working rear lights so i took them apart and clean all the contects.

 

before

 

​

 

before VS after

 

​

 

 

no , it's not a new rubber just a very clean one

 

​

 

i restore the clock as well (it was very dim)

 

​

 

as you can see the sunroof trim was filled with silicone, the drain holes also

 

​

 

let the cleanning begin...

 

​

 

 

after the cleanning

 

​

 

look how much silicone was there

 

​

 

new spark plugs and recondition fuel injectors

 

​

 

 

​

 

 

i remove the fuse tray from the car to clean the cotects and to check if everything is good inside. also, i checked all the fuses and the relay - they was all OK.

 

​

 

a bit of cleanning

 

​

 

 

new rear 1/4" badges and two jets tank covers

 

​

 

 

​

 

the one that i had was broken

 

​

 

 

​

 

 

new genuine erling gasket kit

 

​

 

 

new fuel cap - the one that i've had was broken

 

​

 

 

i've started to fix all the electrics inside the car..

 

​

 

 

a new rear jet - i didnt' have one when i bought the car for some reason

 

​

[idoari 10]

new rear badges

 

​

 

the cable that connects to the sunroof lock was rusted and stuck so i decided to ovehaul the whole system.

 

​

 

 

fix the battery earth wire with solder and some heatshrink tubing to prevent oil and dirt coming in

 

​

 

 

i've rub down and painted the roof frame

 

​

 

​

 

 

cleaned the sunroof handle from the silicone

 

​

 

 

i saw that the vacuum advance of the distributor was disconnected from the engine vacuum so i've fix that as well

 

​

 

 

broken wire fixed

 

​

 

​

 

​

 

i've removed the whole engine loom to fix all the broken wires and clean all the connection properly

 

​

 

new sunroof handle seals

 

​

 

red trim

 

​

 

cleanning

 

​

 

clean with 95% alcohol

 

​

 

after

 

​

 

 

also, i've tested all the light bulbs to see if they're ok

 

​

 

 

new sunroof locking cable

 

​

 

 

new oil filler cap the one that i've had was broken as you can see

 

​

 

 

​

 

 

​

 

 

the new cable fitted

 

​

 

brand new ignition amp

 

​

 

 

the engine sensors loom. i took apart all the wires from the connector , measure the distances that i need, solder new wires with heatshrink tubing.

 

​

 

 

a piece that my dad made to pull the new sunroof locking cable

 

​

 

 

 

​

 

 

the new engine loom finished. i will need just have to cover all the tubes with black tape but that's about it.

 

 

enjoy

 

Ido

Edited November 25, 2014 by idoari

[allye 530 3 Cars]

Absolutely brilliant, for me these are the most satisfying projects being completely de-chav'd and saved. Car is getting some love for the first time in a long time.

[jackherer 543]

As above, good work

 

Good parts sourcing too

[idoari 10]

thanks guy it's not that easy so source the parts since all the parts i have to import from UK or other place in europe.

we don't have any new parts for 205 anymore in israel :\

[2052NV 24]

Wh ever owned that car before you needs to be banned from owning a car!!!!!

 

Brilliant work mate

[acox99 74 1 Cars]

Good work. Will be a really nice car when finished.

[idoari 10]

i wasn't updating for a while but things moving with the project...

 

i find out that one of the previous owners put a tinting stickers on the windows and the glue started to stink (probebly from sun exposure) so i've remove them with alcohol.

 

‹

 

i replace one of the vacuum hoses and the long vacuum hose that goes from the brake booster to the distributor was missing so i made one and put it there.

 

​

 

i've covered the whole engine loom that i fixed with tape to protect it from moisture and oil.

 

​

 

i've visit a scrap yard and got some goodies

 

​

 

complete dashboard

 

scuttle panel with no brakes ( a little cleaning won't hurt )

 

​

 

sunvisors (one has the mirror missing)

 

 

new complete steering columb trim

 

​

heater control

 

​

 

battery clamp (don't worry it will be painted)

 

 

cleanning the scuttle ( there was a ton of mud and leaves inside and the side drains was completely clogged)

 

​

 

after cleanning

 

​

 

painting the battery clamp and the MAF bracket

 

 

 

 

battery clamp installed

 

 

old vs new heater control i've cleaned the contacts and oil all the cogs

 

 

heater fan old vs new (guess which is which )

i've cleaned the new one and oil it.

 

​

 

sunvisors installed

 

​

remove the back seats to see if the fuel pump wiring is OK and to extract the seat belt from underneath also to be able to remove the carpet for cleaning.

 

​

after cleaning and oil the seatbelts female sockets

 

 

after removed the carpet

 

​

 

before vacuuming the carpet

 

​

 

after (not much of a difference but i will wash it tomorrow)

 

 

enjoy

Ido

[idoari 10]

just a little update i finished to wash the carpet today. i work on it for two hours with hot water, washing powder and hard brush. after a once over i've cleaned the remaining stains with dish soup and hot water and the result before you.

 

i think it came out beautifully.

 

​

[Pugleyrich 37 1 Cars]

Coming along nicely. That carpet looked heavily soiled in the back! Good work

[idoari 10]

in the past few weeks there was some progress...

 

i install the o-ring for the sunroof handle and check for leaks

 

​

 

i've had a fuel smell inside the car so i removed the rear seat to get access to the fuel pump, i've removed the pump and cleaned the bottom filter and fixed the wiring for the fuel pump and put hot melt glue on it to prevent moisture to get in,

 

​

 

i removed the seat belt retainers and the front seat rear mount and painted them black.

 

​

 

​

 

i cleaned the car with compress air

 

​

 

and installed the cleaned carpet back inside

 

​

 

installed the seat belt retainer back

 

​

 

i've went to the junk yard and get some goodies

 

​

 

​

 

overhaul the gear stick

 

​

 

​

 

before state...

 

​

 

the gear stick that i got from the junk yard is form 205 TOP XRI and apparently it's different from the GTI one in both length and gear selector angle.

 

​

 

the only reason that i wanted a new gear stick is because someone that got the car before me cut the head of the gear stick so i cant get the original gear knob on it. so in the end i went withthe GTI gear stick but i cut and weld the gear stick head on it (and painted it silver for rust protection)

 

 

​

i've painted the rusty bracket, cleaned the old grease ,put new one in and reattached the whole thing

 

​

 

now i can install the gear knob

 

​

 

i'v got some rear axle kit

 

​

 

installed the new ignition amp.

old vs new (in the bosch box)

 

​

 

put some thermal compound

 

​

 

and surround the whole thing with silicone to prevent dirt and moister to get in. i've also painted the braket that hold the amp black.

 

​

 

the engine keep stalling so i've remove the spark plugs and the two in the middle was dipped with oil.

 

​

 

i've cleaned the oil with fuel to remove the oil and use a wire brush to clean the electrodes.now the engine running much smoother but still not prefect.

 

got some oil and filters for the car just i need to replace the coolent to zerex one because i've heard prestone isn't good and i've got the wrong oil filter. the seller told me the 1109.AP is the same as the 1109.AL but it's not there is not valve inside.

 

​

 

Ido

[idoari 10]

ok a lot of updates....

 

i had a terrible water leak from the intake manifold so i've removed it.

 

​

 

i've cleaned the inside of the manifold with petrol and brush - it was very dirty inside as you can see.

 

​

 

i've cleaned the throtle body as well

 

​

 

i've cleaned and tested the alternator (since it didn't charge the battery) - now everything fine

 

​

 

the bolt that's responsible for the alternator belt tension was broken so i've replace it and paint the braket black

 

​

 

the new fuel filter

 

​

 

the manifold after cleanng and installing the new fuel injectors

 

​

 

the throtle body after cleaning

 

​

 

 

when i bought the car the heater matrix was disconnected

 

​

 

so i connected it and it was leaking so it will be replaced

 

​

 

 

new stuff - genuine oil filter , genuine coolent , new vacuum line , new coolent gauge sender and new fan switch

 

​

 

 

i've resoldered the broken wires for the fan switch and install it

 

​

 

 

i've cleaned the MAF sensor with this cleaner - just in case ​

 

​

 

 

i've removed the fan blower transistor from the car and test the transistor and it was bad so i've replace it (i put themal grease under it and silicone around to prevent moisture to get under. also i've cleaned and solder the whole thing)

 

​

 

 

​

 

 

i've drained and filled the gearbox oil - this is the old stuff

 

​

 

 

fixed the front fog light - both of the wires was broken

 

​

 

 

i've got new rear axle nuts and covers and new sump plug

 

​

 

 

cleaned the seats

 

​

 

 

from the moment i've got the car - i saw that in the past the master cylinder was leaking and eat the paint

 

​

 

painted it...

 

 

​

 

 

the genuine air filter box and pipes

 

​

 

 

the air box was rusty so i've painted it

 

​

 

 

cleaned the old sponge from the back of the dashboard

 

​

 

and put a new one

 

​

 

 

 

new oil temp sensor

 

​

 

i've got the sunroof rubber seal and some vents

 

​

 

 

 

cleaned the SAD with carb cleaner

 

before...

 

​

 

 

after

 

​

 

​

 

i had a broken MAF gasket - so i made new one

 

​

 

 

it's made from special paper and i've put grease on it to help it seal.

 

​

 

 

the airbox and pipes installed

 

​

 

 

the old oil that was in the car - it was dirty and black

 

​

 

 

the sunroof seal installed

 

​

 

 

i've got interior light

 

​

 

new genuine air filter

 

 

 

new coil

 

​

 

 

that's it for now

enjoy

Ido

[Plumbob 66 1 Cars]

Nice one! That car can hardly have worked at all when you got it! Keep it up!

[Alan_M 66 1 Cars]

Great work.

 

I must ask though, where are you getting the parts from as I guess a 205 GTi wasn't a popular car in Israel!

[idoari 10]

98% from them from EBay Uk or EBAY germany.

[Slo 283 1 Cars]

And people in the uk moan about parts prices lol nice work Ido love the passion

[eddie bullit 37]

Looks like you're doing a great job! Good luck with it. I'm looking forward to seeing the finished result!

[idoari 10]

And people in the uk moan about parts prices lol nice work Ido love the passion

If i was in the UK my car was a show car. everything is expensive to ship and you think twice before buying anything.

 

thanks 4 your support guys

updates coming up soon...

 

Ido

[idoari 10]

i didn't had time to update , now i have.

 

new heater matrix

 

​

 

new ECU temp sensor (genuine bosch)

​

 

 

new genuine thermostat (i ordered the wrong type the correct one on the way)

 

​

 

cleaned the MAF sensor

 

​

 

​

 

 

installing the heater matrix

 

​

 

new timing kit

 

​

 

new HT leads i got a good deal on them so i ordered them (they are the R-100 not the KV-85)

 

​

 

new gear linkage

 

​

 

instrument cluster i GREAT condition ( will be painted black to match my interior)

 

​

 

new exhaust fittings

 

​

 

new leather gaiter (the smell of new leather....I LOVE IT)

 

​

 

interior lamp and sunvisors installed (the lamp wiring loom was fixed also and tested)

 

​

 

painted the sunroof trim black ( i really need a new set the one in the middle is broken but glued)

 

​

 

new HT leads installed

 

​

 

look at the thickness comparison - massive differnce , the engine is running a lot smoother with this as well ;ׁ)

​

 

timing job

 

​

 

new water pump

 

​

 

before cleanning the water pump housing

 

​

 

after ( the white stuff is from the inside and it's not silicone so i left it alone)

 

​

 

new tensioner

 

​

 

ECU temp sensor installed

 

​

 

the thermostat that i ordered by mistake is for 205 TU engine and it's doesn't fit so i tested and install the old one until i get the correct one.

 

​

 

i painted the dashboard from grey to black with proper leather dye

 

​

 

the result (it came out fine by bit too shinny - i'm sure it will fade with the sun)

 

​

 

i got a washer tank that was missing from my car

 

â€

 

 

that's it for now

comment are welcome

Ido

[Plumbob 66 1 Cars]

Nice work, well done.

[Slo 283 1 Cars]

Bit of a fail on the dashboard colouring there, all you need is some black satin aerosol and it will look original black perfect

[idoari 10]

Bit of a fail on the dashboard colouring there, all you need is some black satin aerosol and it will look original black perfect

i could do it with aerosol but aerosol will peal off over time and this dye won't.

remember that i needed to CHANGE my dash color from grey to black so i needed something to bond to the surface and not just lay on it.

Edited March 31, 2015 by idoari

[Slo 283 1 Cars]

it wont peel off if you wipe it down first remember this is inside not outside side where the elements are

[idoari 10]

it wont peel off if you wipe it down first remember this is inside not outside side where the elements are

maybe not all the elements , but the sun will do it. Israel is warm climate country.