buzzbrightyear
Post #1
i wanted a brand new 6 and seen as the one i have has 126k miles and was still in extremely good condition: 
i decided to keep her and just renew the whole suspension eg to freshen it up, anyway i got a bit carried away.
i started buying and collecting parts a long time ago, i couldnt see the benefit in fitting them one by one as and when i could afford it, so i just saved them and kept buying. the clutch then went so i took the car off the road and it started there, the car has been on axle stands for over a year, the neighbnours must think im an idiot polishing a car thats got no wheels on!!
i want to go and start doing some trackdays in the car but still wanted to use it on the road from time to time, so i decided on the following suspension setup:
1: bilstein b8 front shocks and b6 rears
2: eibach 30mm pro springs
3: hybrid rear arb
4: estate tosion bars 21mm i think they are
5: solid rear beam mounts
6: richw solid roller bearing wishbone bushes
7: top mounts, arb bushes, balljoints, track rod ends, bump stops eg all replaced for genuine peugeot parts.
8: rear beam rebuild
9: all nuts and bolts replaced with new from peugeot.
10: new driveshafts both sides, from ecp and gsf.
well after getting the gearbox off i noticed that there was a small oil leak that looks like it comes from the crank seal, but its actually from the last crank bearing cap, so the sump came off also so that could be fixed:
.
a nice new seal was fitted to the bearing/crank carrier and a new crank seal from pug, i gave the sump a good clean up and refitted:
then set about fitting a few other bits around that area like the group n gear rods, a new fulcrom/rubber ball for the gear linbkage and a lightened flywheel!!
before the gearbox went back on i thought i would sort the bit of rust out on the p/s engine bay inner wing and bulkhead and a bit in the corner near the sill from where the underseal had been marked from a jack.
i taped off all the surrounding area, and i cleaned up with a wire brush in a cordless drill then followed by the rust treatment called bilt hammer gel:
did the paint work with primer then a stone chip then the original moonstone, you cant even tell its been done barelyi did a real good job but cant find the pics so will take more.
gearbox is fitted back in with a standard valeo clutch, group n mount, new fork bushes, driveshaft seals, the seal that goes on the splined shaft that fits through the clutch was changed (sorry forgot its name), clutch cable replaced and a new clutch fork was used as i had to bend the arm to remove the gearbox and it comes as a kit with the arm eg.
i turned my attentions to the other side of the engine bay and removed the cambelt and tensioner eg, water pump, aux belt tensioner and roller.
i suspected the little tank near the water pump to be leaking so removed that also to inspect the hose and fit a new seal.
thermostat was removed for a new one, i then decided i was going to get some bits tidied and painted up while it was in bits.
i removed both cam covers and front carrier, the thermostat housing and the fuel rail, after removing the fuel rail i noticed a plactic cap missing so that was an excuse to remove the inlet for painting also!!
all the bits were cleaned thouroughly with a wire brush bit in a drill again:
to save the process pics heres a few finished ones:
i decided on a mattalic dark silver from a lamborgini for the fuel rail:
.fitted the cam carriers with new camshaft seals, the cariers were sealed with the same stuff as the sump, i got it from pug but i bet its way cheaper elsewhere:
refitted the cam covers, then the thermostat housing and popped a new thermostat in there.
the little tank near the water pump that i removed was refitted with a new seal and a new pipe, there was nothing wrong with them, it would of just been silly to not change them for the price, and i dont want any problems later on,
old water pump looks a bit manky:
ne pump fitted, new cambelt and 137 kit (what came up for my reg on computer at dealer).
a rich w lightened crank pulley was used and then a new aux belt and uprated tensioner and roller was used. throttle body removed and cleaned, new gasket fitted then inlet manifold is refitted with a ptfe inlet gasket and stainless steel bolts, a new boscsh tps and map sensor are also fitted at the same time:
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andrew315rawson@live.co.ukMoonstone phase 7 gti6
My Project thread: http://www.306gti6.com/forum/showthread.php?id=119992&page=1
Posted 26th Feb 2010 at 01:50
