[car_overhaul] Pug 205 Engine Rebuild + Twin 40's

[phonecomz 0]

Many years have passed having owned loads of other cars, bm's, mercs, lotus etc and i had not touched a 205 for the last 13 years.

 

Prior to that i have had 14 of em as i recall, including 6 XS's (love em!) 2 x 309 goodwoods and rest 1.6/1.9 gti's... and their was me thinking as i now work with range rovers, i would see a another... Guess what... could not resist.

 

Just before christmas i bought another 1.9 Gti 1992 K plate in Graphite

 

 

http://i84.photobucket.com/albums/k21/phon...0k/000_0037.jpg

 

The car has had a full respray and looks the part with new mouldings etc, however driving her home she ran fine, though arriving home i dipped the oil and found 1 litre of oil left in her, 4 litre's in 150 miles ?

 

Anyway no visable smoke was apparent all the way back and nothing on drive after leaving it over night, so i had to investigate futher

 

With the current mileage at 112k i thought id plan a little project and strip it down and start rebuild her, with some extra's of course.

 

 

A tired looking engine bay with heavy dried oil staining at front ....

http://i84.photobucket.com/albums/k21/phonecomz/9d_3.jpg

 

Having no premises now i managed to persuade my father to borrow his garage(single) for a while and 2 days ago i removed the engine, everthing i seemed to remove was either broke, modified by amatuers, or boddged. Even the radiator, though it is new, was leaking after someone boddged the plug with some orange sealer having overtightening it and snapping the thread off.. thats now fixed with a new plug..

 

http://i84.photobucket.com/albums/k21/phon...0k/000_0041.jpg

 

http://i84.photobucket.com/albums/k21/phon...0k/000_0040.jpg

Rocker cover is a differnent one used for cleaning as other one taken off to polish in case your all wondering also patio, flags, window frames did come clean eventually

 

The Engine and box removed and 1 hour later after using cleaner (but before steaming) the difference between the engine and gearbox shows the extent of the oiling.

 

whilst removing the engine the problem with the oil loss was dicovered. The car was using the the remote type oil cooler on the gearbox and one hose had a massive split at the the top... answering the oil loss.

 

http://i84.photobucket.com/albums/k21/phon...0k/000_0043.jpg

Plan is now to strip engine and clean, paint, check and replace all internals.

 

Also will be repainting engine bay and replacing front panel (Due to small amount of damge from the past) Not bad, but bugging me.

 

Also have a totally reconned head going on with a piper 270, new valves, guides, piper belt. etc

http://i84.photobucket.com/albums/k21/phon...0k/000_0039.jpg

 

also a pair of twin 40 dhla with a facet pump, ITG Filter, 4 in to 1 magnex full system, uprated clutch, group n mounts, samco hoses and loads of whatever else i have purchased and forgotted about.. or that might fit the expanding budget

 

thought id all share it with you as might get more intersting as ive forgotten most of it and i'll probably get stuck with something, like wiring after changing to carbs. Not sure where to mount the newer type coil as yet, any suggestions appreciated, or extra advise

 

Ps if anyone got a spare crankshaft pulley please let us know as some idiot has cracked back edge of mine with wrong puller, thanks

 

 

will Update when possible, Car at fathers house so work on it every few days when i go up, Wife pregnant too and plenty of range rovers jobs keeping from my new pug.

 

edit; image sizes & quantity. if the image is greater than 120k in filesize put up just a link, without IMG tags.

 

If you are showing off your car from several angles, use IMG tags only on first

couple of pics and link the others but if your showing a progress of some work or

something technical, you can use IMG tags on all the pics, providing the pics are

pretty much different.

Edited January 9, 2007 by pugtorque

[welshpug 1,661]

1 litre left in the sump when you stopped? sounds about right!! takes a while for the oil to drain back into the sump after running the engine...

 

nice project, opposite to mine as the mechanicals on mine are good now.

[Richie-Van-GTi 72 2 Cars]

thast a mint looking car, will be awesome when the engines all done and sorted

[Super Josh 4]

Ps if anyone got a spare crankshaft pulley please let us know as some idiot has cracked back edge of mine with wrong puller, thanks

 

 

They all crack after this number of years, you'll have a job finding one that isn't. I just clean up the sharp edges with a needle file and away you go.

 

 

 

 

 

Josh

[phonecomz 0]

thast a mint looking car, will be awesome when the engines all done and sorted

 

thanks for the comments guys ! I suppose i could just clean the edge up as it does not interfer with the belt, i guess im a bit over fussy i think. I'll still hang out for one if someone has got one. ... ?

[Longun 1]

Great looking car and should be great once finished but can I ask why you went for the 270 cam? I was told it was almost the same as standard? Of course there is a chance I'm wrong as normal Also you can't beat the sound of carbs

[phonecomz 0]

Great looking car and should be great once finished but can I ask why you went for the 270 cam? I was told it was almost the same as standard? Of course there is a chance I'm wrong as normal Also you can't beat the sound of carbs

 

Hi - I had the cam 270 cam kit kicking around basically that had never been fitted so i thought i would use it.

 

In hinesight i think if i had the choice i would have gone for a 285/295 or such but with the head as std and not being gas flowed or such i dont think a larger cam would have made much differnce without doing some extra work. Been better with a xu10 head with larger valves i guess.

 

The head im putting on still bothers me as i would have liked to use an xu10 head with larger valves and ported really. Things may change yet

[Longun 1]

Yea if I had one lying around I'd have used it too At least this way you can get it running and when time and money agree get a second head built up whist still using the car Is it going to be a daily drive too? At least with that cam it will run better day to day.

[phonecomz 0]

Yea if I had one lying around I'd have used it too At least this way you can get it running and when time and money agree get a second head built up whist still using the car Is it going to be a daily drive too? At least with that cam it will run better day to day.

 

More of a weekend car at the moment, as i run a rangie through the day, but depends on the smile factor wehn done . 205's gets very addictive as im sure you would agree. yes i will try it first then see what its like..

[findlay 0]

Wow thats another great looking 205 and the bolster has lasted surprisingly well for 112k too! Like it a LOT!

[number2301 1 1 Cars]

That's one shiny Graphite!

[phonecomz 0]

Wow thats another great looking 205 and the bolster has lasted surprisingly well for 112k too! Like it a LOT!

 

thanks for the comment. Bolster has had some sort of repair, all be it pretty poor really due to it being stuffed and stiched from the outside. Will be taking seat to pieces shortly to change incorrectly welded frame and repair bolster again.

[phonecomz 0]

Well another day and another having caught crap cold and flu i thought what better time to go and start shivering and fixed up another part...

 

 

this morning it looked in a poorly state

 

 

Completly stripped cleaned.

 

finally tonight

 

 

http://i84.photobucket.com/albums/k21/phon...0k/IMG_6102.jpg

 

http://i84.photobucket.com/albums/k21/phon...0k/IMG_6104.jpg

 

Just need a pick up lead now as mine is stuffed. I had another but thats just as bad. anyone know how much they are ?

[phonecomz 0]

Ok - time for another quick update guys and girls...

 

 

Well after stripping the engine i found a set of nasty big end bearings, 2 completly bronzed and two had picked up and taken chunks out.... Mains were a little better i guess...

 

Undoing the bearing caps i found them to have massivley different torque settings ...

 

After measuring the liners i found that they were actually quite good with a minimal lip, so, after a quick hone in my machine shop and checking for ovality their now A1..

 

Spent many many hours cleaning and painting block. A good tip thats seems to have always worked when painting them is to use a few coats of high temp laquer after the base coat.

That way, even after a few months, it cleans off really easlily again. I found with non laquered painted blocks together with a combination of heat, road salts and general grime it just absorbs back into the paint and does not come off ...

 

 

 

 

Before christmas i dropped on someone selling a garage full of parts...

 

The chap had started an engine rebuild project and had given up, so i purchased the short engine off him with a view to using many parts from this block.

 

http://i84.photobucket.com/albums/k21/phon...0k/000_0049.jpg

 

It had some work already done, including new shells, the pistons and rods have been chemically cleaned and crank had been balanced. ... though it had been left to stand and the crank and rods had gone a little rusty (though not the journals). I did not wish to use this block as it has been welded, although its a good job and i have tested it just for the hell of it and it is absoutly fine i still have decided to use my old one and sell this one.

 

Pistons and rods, although virtually the same in appearance (apart from some minor castings) are much lighter ? not sure about this ? were they lighter in previous engine from the later XU pistons and rods.. i can t recall ? If not im wondering what they are from...

 

Crank, pistons and rods have been recleaned and checked and are fine...

 

been finishing some other parts too

 

 

http://i84.photobucket.com/albums/k21/phon...0k/000_0051.jpg

 

http://i84.photobucket.com/albums/k21/phon...0k/000_0046.jpg

 

sump was dented (arnt they all) but managed to get it back to bare metal/rust free. Then after watching a program on Sky about making steel drums i got inspired and took it out on my sump, have got it dentless now ... After i have etched it and painted it black again.

 

 

 

will be updating again over weekend, got everything to rebuild so just need the time and my very understanding pregnant wife to nod off for a few hours and i can get some more done

 

Went for a scan yesterday to see how the baby's doing... all ok... spooky thing was i recall thinking how usefull it would be the next time i came to get some parts on the table also... HE HE

[allanallen 528 2 Cars]

lookin sweet, your into your polishing then!!!

[Longun 1]

This is going to be one clean, quick 205 can't wait to see it finished Keep us posted

[phonecomz 0]

thanks longun, will keep updating as and when possible,

 

 

Yes Allanallen I Started polishing a few bits, slow but it's worth it in the end i think. Not wanting it to look over the top though so only doing a few bits..

 

forgot to mention earlier, crank, pistons and rods / clutch cover now balanced. Did them independantly then together to be sure. Flywheel is already lightened.

 

hoping to get loads done tomorrow

Edited January 27, 2007 by phonecomz

[allanallen 528 2 Cars]

forgot to mention earlier, crank, pistons and rods / clutch cover now balanced. Did them independantly then together to be sure. Flywheel is already lightened.

 

you seem to know what your doin, I take it you do this sort of thing for a living?

[Richie 32]

Judging by the car in its current state, and the work you've done already, i can tell thats going to be wicked. (havnt used that word in a while lol)

[phonecomz 0]

you seem to know what your doin, I take it you do this sort of thing for a living?

 

 

I specialize in Range Rover p38 Servicing Mobile, but also work on Merc, BM's Audi, VW, Pugs (of course) etc... Well just about anything that anyone throws at me i Guess. Worked for dealers for some time then went independent...

 

 

Judging by the car in its current state, and the work you've done already, i can tell thats going to be wicked. (havnt used that word in a while lol)

 

thanks fella, i hope it turns out pretty wicked too... at present im just hoping i get it finished before next christmas... lol Its all the cleaning and prep work that slows the job down

[phonecomz 0]

I promised a weekend update so here goes,

 

got round to checking and assembly today again so started with the crank from the donor engine as it proved to be in far greater condition than mine. Checked bearing clearance with platiguage

 

 

 

 

After checking, all ok. New shells removed and cleaned from old block and transfered to my block as they were brand new, using my end caps though to match block of course.

 

I then Checked the end float using a dial guage and this also was within tolerance

 

http://i84.photobucket.com/albums/k21/phon...th/000_0058.jpg

 

http://i84.photobucket.com/albums/k21/phon...th/000_0055.jpg

 

Next job was to reasemble pistons and liners. As mentioned previousley i am using the pistons from the donor and rods as they are lighter than mine and like new.

 

The new rings he had fitted in the donor gave me a near border line ring gap, so i have ditched these as i had another set which gave methe gap i was looking for. So after cleaning rods i put the pistons back into the liners and place them back into my block with new liner seals...

 

http://i84.photobucket.com/albums/k21/phon...th/000_0063.jpg

 

Next i torqued big end and mains up

 

http://i84.photobucket.com/albums/k21/phon...th/000_0064.jpg

 

 

 

added oil pump, oil seal housing(with new seal) applied a 3mm bead of dow corning RTV Sealant to spacer and replaced the sump. Also fitted the water pump and rear engine mount.

 

 

 

http://i84.photobucket.com/albums/k21/phon...th/000_0065.jpg

 

http://i84.photobucket.com/albums/k21/phon...th/000_0066.jpg

 

http://i84.photobucket.com/albums/k21/phon...th/000_0068.jpg

 

 

I then got round to fitting the distributor housing back to the head and also replaced the Inlet studs (old one's well past it).

 

 

 

http://i84.photobucket.com/albums/k21/phon...th/000_0061.jpg

http://i84.photobucket.com/albums/k21/phon...th/000_0060.jpg

 

and finally for now i have just place head back on block with bolts just placed their for now until i can get back to the job..

 

http://i84.photobucket.com/albums/k21/phon...th/000_0067.jpg

 

thats all for now folks, until i get some more done...

[Boris 0]

good work.So clean .

[phonecomz 0]

Well i know a while has passed but time once again for a short update.

 

Wife is pregnant, as i mentioned in the past and has had some heart trouble, so put project on hold for a while until things have settles down.

 

As you can see i still have been busy i have finished gear box and engine after many long spare hours in to produce this, which i think has turned out quite well so far.

 

 

 

 

http://i84.photobucket.com/albums/k21/phonecomz/000_0074.jpg

 

http://i84.photobucket.com/albums/k21/phonecomz/000_0073.jpg

http://i84.photobucket.com/albums/k21/phonecomz/000_0071.jpg

 

Have the odd finishing touches to complete, ie exhaust studs, but it's nearly there.

 

Next i will be removing front subframe to change for the 309 one i have aquired. awaiting some bushes and stuff first.

[pug309twin40s 1]

wow, so clean and shiny!!!

 

far to clean to be in an engine bay. look better in a museam lol

[24seven 104]

If only I had the facilities to even try and do something similar! Stunning job you've done on that!