[car_restoration] Sorrento Gti16v Full Rebuild

[jackherer 543]

I'm pretty sure the 205 and 309 upper columns are identical, I've used 309 ones at least twice in 205s with no issues. It looks like one of yours has shifted internally against the bearings or something, the extra length you identify seems to be missing from the opposite end.

[de Noir 0]

could be, and servicebox said they should be the same..

they differ in detail though, and also have different factory number stamped on the body

Edited August 18, 2010 by MH_

[de Noir 0]

Right, 'new' old steering column and new old power steering cylinder solved the steering issue.

Shorter 8v driveshaft fitted, no more knocking and vibration when turning.. Great news, then!

 

Changed the engine oil for the first time, everything was fine and I set my wheels to the coast for a test drive.

Car was behaving just perfect in every way, except the idle speed.

Although still running-in and revving gently only to 4-4,5k thus unable to extract the full potetial, I was really enjoying my time with her...

 

 

 

...up to last few kilometers from home.. When an unwanted sound mixed in the engine simphony.

 

Halted on a motorway station to take a look. It sounded like something's gone wrong with valve hydrolifter.

On a fully rebuilt engine! Almost all parts fitted were brand new!

 

Wasn't prepared to take any further risk, called the tow and went for a coffee...

 

She's at the shop right now, waiting for a closer look / diagnosis.

Starts without problems, on idle runs steadily. Drives fine too, haven't noticed any loss of power.

Just this horrible typing-machine klicking sound!

 

 

Not in a much of a mood right now.

Edited August 31, 2010 by MH_

[Edp 67 3 Cars]

Dosent sound good, good luck!

[de Noir 0]

Cheers Ed, hi all.. Introducing a new name here

 

 

At the end of the day, inspection done: nothing was wrong with the engine!!

 

Cam cover off, visual inspection, cleaning job, everything was fine, cam cover back.

New 5W50 full synt oil + oil filter instead of 15W40 I have used for two oilchanges during the running-in process.

 

Engine start, typewriter knocking sound no more.

 

 

I can not explain this.

Only thing that falls to my mind is that some dirt may have flown in the hydrolifter and blocked it from working properly.

 

Idle speed fixed too, TB needed some further cleaning and adjusting, finally I got 'steady' offbeat 950-1000 rpm.

 

 

 

Engine is running fine, I have revved it up to approx 6500 rpm, no more road left... She's really fast.

 

 

[vinorak 4 1 Cars]

great story and nice car , someday i will have griffe gti16

[de Noir 0]

Thanks!

 

 

Anyway, issue with the engine had continued and whole story doesn't look too good at the end.

 

Cam cover removed, cams & cambelt down, tappets out - revealed at least three tappets had obvious malfunction - visually perfecdt but leaking oil.

 

Next, parts wholesaler wouldn't accept guarantee exchange as more than a year passed from the purchase date...

Nevermind the engine has run only for 900kms to the first rattling sound that disappeared by itself, and some 1500-1600 to the second coming which stayed!

 

'The best' he could do is to suggest a purchase of WHOLE set of 16 tappets (as you may imagine, costing a lot of €€€) :glare:

 

Such unfriendly attitude ended with me ordering four tappets from Peugeot - arrived and waiting for install - this should be sorted next week if ain't already, me not knowing.

 

 

Thing that puzzles me here the most is why this had happened at all!

 

I have never ever heard new tappets have gone wrong! This including tappet set exchange on my ex 306S16, done by mate and me in my courtyard one warm sunny afternoon few years ago...

 

This engine has been assembled in a very tidy fashion from chosen quality parts and the guy who did it gave the lifetime guarantee on his job.. Also, run-in procedure was spot-on, with no unneeded idling or similar stuff - tappets and cams visually perfect, car runs like stink, no smoke at all - three oilchanges in 1500kms, oil pump and chain new, etc, etc.

 

 

The whole story just doesn't blend!

Wasting bucketloads of money and time into an engine rebuild - with such a stupid epilogue, as this!!

 

 

My best shot is that some part of dead metal or untidy job leftovers ended in the tappets and ruined the story.

Will check the dead tappet leftovers myself as soon the car is done by the garage... :glare:

 

 

At the end, I kindly ask you, has anyone had similar experience?

 

 

 

 

 

Never the less, things ain't as noir as expected.. Did some detailing in the meantime:

 

The cassette HU blending-in nicely, sounding not so nice at all

 

And suede wheel finaly fitted:

Edited October 24, 2010 by de Noir

[de Noir 0]

 

 

 

 

first trackday stint started just perfect in every way, but ended with blown engine soon afer, in second timed lap

 

it happened in fast sweeping left hander

enigne coughed tk-tk-tk two-three times like I have had reached the limiter

quick look at the tacho revealed I was far from it

next moment went BANG

 

everything happened in split second

 

have no guts to perform detailed inspection..

but when you lift the bonnet, you can clearly see crankshaft lurking out from the hole in the engine block

 

 

towed tha car back home, i'll leave it for a while, then decide which way to take

Edited October 30, 2010 by de Noir

[GLPoomobile 958]

f***! That is some really, really, really rotten luck

 

But whilst you are sorting out the engine, get that license plate back on the bumper

[Edp 67 3 Cars]

bugger......

[FicaGTI 0]

F*****g S**t! Unbeliveble, good luck with repairs!

[CallumCurwood 1]

Jusr read every page from start to finish. Was such an amazing build. Sorry to hear about the engine, hope you get it sorted soon (Y)

[de Noir 0]

thanks.

 

 

in the meanwhile, got myself bare 'new' D6C engine:

 

 

 

the plan is to use inlet/exhaust, electrics and auxilliaries from the blown one and I'll be operating again till Christmas

[de Noir 0]

Transplantation finsihed, we're back!

 

 

Broken conrod was the clue.

 

Photos:

 

front

 

closeup inside

 

back

 

closeup

 

conrod and piston remains:

 

 

 

I got her on the road again, need to drive around for a while to burn the oil spill letovers thru the exhaust etc..

 

New old engine looking good, for now.

[Ludi 2 2 Cars]

After reading all the story..............WOW.

 

I'm glad that you sort everything,and honestly hope that is going to stay that way.

 

It's always nice to see such a love with 205.

[dale205mills 39 7 Cars]

I hope you will put one of them pictures on your workshop wall and be proud to tell every one I done that.

[de Noir 0]

well, I am actually not very proud of this blown engine episode at all!

[un numero d'or 38 3 Cars]

Have had some lovely reading for an hour, hats off mate!!!!Great project indeed:)

[de Noir 0]

thanks.

 

 

a video of me on 'that' trackday surfaced recently..

here, clocking 190kph at the end of the straight, probably taken half a lap before the engine blow:

 

 

[de Noir 0]

Got her back on the road, new old engine details sorted and weekend-tested, looking good and going strong so far.

 

I'm back!

 

 

 

 

Here two old rivals meet, back to the future style:

 

 

[Edp 67 3 Cars]

Loving that picture with the renault 5

[de Noir 0]

Thanks Ed, I do not even know the guy with Renault - I guess he was on a sunday drive and stopped for coffee as I did.

Anyway, I need to make some decent piccies ASAP..

 

Mechanically and visually everything's sorted now.. Well almost..

Yesterday when putting her back to sleep after a drive I heard kind of rattling sound from one (of two) cooling fans.. Should I leave it or should I taste it?

 

 

Near future plans include sorting ICE, got some nice stuff lately..

Edited March 7, 2011 by de Noir

[de Noir 0]

washed, polished and waxed..

I begin to appreciate professional car detailing stuff more and more.

 

 

Edited March 15, 2011 by de Noir

[irmscher 0]

some great pictures and enjoyed the read

[de Noir 0]

pulled the ultimate hard test in the Alps!

 

4 days on magnificent mountain roads of Austria and Italy

20 alpine passes

1900km

160 liters of petrol

 

And not a single issue!

 

Photo selection here:

 

 

 

 

 

 

 

 

 

 

 

 

and finally, back home..

 

 

 

cheers!