Rebuilding My Engine.

[Guest wils3]

I have a 1989 F reg 1.6 205 GTi which i plan in the near future to rebuild the engine/transmission in it.

 

The car i believe (checking engine/chassis codes) has its original engine which has clocked 105k.

 

The engine is i believe an xu5ja.

 

Now this will be my first time by myself rebuilding an engine but have in the past help my dad rebuild an engine, and done work my self on motorbike engines, so im confident in doing but will take precautions as still really a learner.

 

Now until the engine is in parts i wont properly know what i need doing to engine but i will be replacing all the common bits piston rings, gaskets, bearings etc.

 

Question Time:

 

1.

The xu5ja engine is the alloy lump with the cyclinder liners right?

 

2.

Going by what you lot have seen when rebuilding engines, Do you think my cyclinder liners should be ok for refitting back in? Engine has done 105k.

 

3.

I was intending to replace my exhaust valves and was reading in haynes manual about grinding in new valves with the rubber suction cup stick tool thingy and thought about giving it a go,

 

then read on net somewhere about ''Multi Angle Valve Seats'' are a must so can someone please explain to me how these work, what they do, how are they fitted, are they worth fitting/getting fitted?

 

4.

I dont have an engine crane/lift, but over at where my pug is i have use of a nice new caterpillar forklift so will be moving forks fairly close together depending on where engine/transmission hooks are? Can some one tell me, where are the lifting hooks, best places, as i cant really see nothing in haynes???

 

5.

How heavy is engine and transmission together roughly in kgs, as i dont have any metal lifting chains just rope.

 

Thanks

[pacey205 2]

1. Yes

2. Youll really just have to have a look when you get them out to be honest its diffficult to judge without looking. My 100Kish Mi though stll had the honing marks.

3. Not dont it myself but many people on here have

4. Forklift will work fin. Engine hooks are by the distrbutor and by teh drivers side engine mount.

5. Id say it was about 120Kgish (Edit - with gearbox manifolds still attached). Never actually measured it myself. Its too heavy to lift by yourself all together though (unless your some sort of beefcake).

 

Tips

1. Bag and label everything, even if your not going to use it again. It might seem inconcequntial at the time but you never know what you might need later on. Its best to keep it just in case.

2. Give everything a good clean before it goes back together, So much nicer working on a no gunk covered engine.

3. The Haynes manual is actually resonably good for the strip down/rebuild.

 

Thats all I can think of now but Im sure theyll be much more advice.

 

HTH

 

Michael

Edited January 4, 2006 by pacey205

[Alastairh 47]

The engine on its own is about 80kg, everything else Pacey has covered.

 

Where abouts in Northants are you mate?

 

www.205parts.com is only up the road and lots of friendly advice available there aswell.

 

Alastair

[Anthony 1,003]

1. The xu5ja engine is the alloy lump with the cyclinder liners right?

Correct. The XU9JA engine (1.9 GTi) is effectively just a stroked version of the 1.6

 

2. Going by what you lot have seen when rebuilding engines, Do you think my cyclinder liners should be ok for refitting back in? Engine has done 105k.

Until you pull it apart you'll not know, but the few engines I've pulled apart with that sort of mileage have had liners in that could be reused fine. I'd recommend rehoning them and turning them round 180 degrees though (as the majority of the wear occurs on the thrust side)

 

3. I was intending to replace my exhaust valves and was reading in haynes manual about grinding in new valves with the rubber suction cup stick tool thingy and thought about giving it a go, then read on net somewhere about ''Multi Angle Valve Seats'' are a must so can someone please explain to me how these work, what they do, how are they fitted, are they worth fitting/getting fitted?

The valves themselves will probably be fine. What likely won't be is the exhaust valve guides, as these seem particularly prone to wear on 1.6/1.9 8v engines for some reason. 3 angle valves seats help to produce a little more flow and hence power - most engine builders should be able to do this for you at comparitively small cost, as well as replace the valve guides if worn.

 

4. I dont have an engine crane/lift, but over at where my pug is i have use of a nice new caterpillar forklift so will be moving forks fairly close together depending on where engine/transmission hooks are? Can some one tell me, where are the lifting hooks, best places, as i cant really see nothing in haynes???

Forklift will be fine (removed engine in the scrappy with one before now) and the lifting points are either side of the inlet manifold - easy to see when you look at the engine.

 

5. How heavy is engine and transmission together roughly in kgs, as i dont have any metal lifting chains just rope.

Rope will be fine providing it's fairly thick - the cheapo nylon stuff B&Q have on a reel I've used before now to lift a good few engine/gearbox combos in and out of cars without any problem. An old seatbelt from the scrappy works fine as well - just make sure you've got decent knots either end that won't pull through.

[Guest wils3]

pacey205:

5. Id say it was about 120Kgish (Edit - with gearbox manifolds still attached). Never actually measured it myself. Its too heavy to lift by yourself all together though (unless your some sort of beefcake).

 

 

Lol im far from a beefcake,

 

 

 

pacey205: 3. The Haynes manual is actually resonably good for the strip down/rebuild.

 

I have the latest manual, one with the square cut out of bonnet on the front cover, and heard the earlier ones are more detailed than than these late ones???

 

Thanks for your reply pacey205,

 

Will look for the earlier haynes now for down #cough# loading.

 

 

Alastairh:

Where abouts in Northants are you mate?

 

I live in Rushden mate but the 205 is at my dads work in eaton socon, cambridgeshire.

 

 

Alastairh:

www.205parts.com is only up the road and lots of friendly advice available there aswell.

 

Cheers mate will have to check them out, but as im not on the road, just up the road to you may be a days walk to me lol, but they always got mail order i take it?

 

Alastairh what scrap yard do you find good round near you? Charlie perkins, is he in kettering?

 

Alastairh thanks for your reply.

 

 

Anthony:

Until you pull it apart you'll not know, but the few engines I've pulled apart with that sort of mileage have had liners in that could be reused fine. I'd recommend rehoning them and turning them round 180 degrees though (as the majority of the wear occurs on the thrust side)

 

 

Anthony is there anyway to rehoning them myself?

Have seen rehoning taking place where i used to work here www.wealdstone.co.uk as a forklift driver so use to have a good nose round lol.

 

I was aware about to turning the liners 180 degrees from reading through this forum for a while now,

 

So my liners that are in now, they will have the markings on them, on the drivers side of car upon removal, so let them sit to 'round' themselves up them when refitting, fit with the markings facing passenger side (gearbox end), correct???

 

 

Anthony:

3 angle valves seats help to produce a little more flow and hence power.

 

 

How do they help flow?

Whats the 3 angle bit all about then?

 

Anthony thanks for your reply.

[j_turnell 137 3 Cars]

Feel free to pop down to us at 205parts mate if you need any advice or guidance

[Guest wils3]

j_turnell:

Feel free to pop down to us at 205parts mate if you need any advice or guidance

 

 

Thanks, Im gonna go to site now and look, will contact you if any more info needed thanks.

 

How far distance/ time wise is, Harborough Road, Kibworth, Leicestershire from rushden, northamptonshire in a tranny van?

[Anthony 1,003]

How far distance/ time wise is, Harborough Road, Kibworth, Leicestershire from rushden, northamptonshire in a tranny van?

29 miles according to AA routeplanner - A6 -> A14 -> A6

 

If it's a white Transit fan, complete with copy of The Sun on the dashboard, you should be able to do it in 20 minutes

[Alastairh 47]

In Kettering theres Charlie Perkins,

 

Frank Beales In Desbourgh beside the air field (although the owner is a tit)

Corby one in the town area just 50 yards from The Hilton or what ever re named hotel it is.

 

And theres another out in the country side in Corby beside a Caravan park, although i don't go there often as its 25 min drive, as again the owner is a tit, and looks at me weird when i say Peugeot

 

And Seaton scrappy out Rockingham way, which is normally good.

 

But if you want 205 bits best speaking to 205parts, as most of the time thay have something or know of something coming in.

 

I can do 205parts in 13 minutes from Kettering keeping reasonably to the speed limits

 

I drive past Rushden Every day for college, so keep an eye out for a Blue 106 xsi...

 

Alastair

Edited January 5, 2006 by Alastairh

[Guest wils3]

Anthony:

If it's a white Transit van, complete with copy of The Sun on the dashboard, you should be able to do it in 20 minutes.

 

Lol no aint a white van man, got royal mail red transit instead lol

 

 

Alastairh:

Yer been on 205parts website, all good, will have to try get up there sometime, just hope the sat nav finds address lol.

 

Thanks for scrappy info.

[Guest wils3]

Alastairh: I drive past Rushden Every day for college, so keep an eye out for a Blue 106 xsi...

 

Do you go along wellingborough road in rushden, past the dark metallic green pug 205 cj or watever it is normally parked on the grass verge near the traffic lights?? Near the oakley pub?