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Author Subject: 205 gti 6
smighall

Smeg-all

Location: b*tching and Whinging

Registered: 03 Mar 2005

Posts: 10,012

Status: Offline

Post #51
That's my point Carl, i understand how they work etc, but never taken one apart. And as you know taking apart is the easy part re-assembling is the tricky bit.

________________________________________

Meh

Seat Leon Cupra FR / 306 GTI6 / Breaking 205 GTI6 / Caterham 7 / Mercedes Sprinter 311CDI LWB

Sold: Fisher Fury - Laguna DCI Estate - P1 306 XSI - E30 BMW 325i Baur Convertible - Daihatsu Fourtack - Suzuki GSXR600 - 205 Rallye
Posted 16th Jul 2008 at 06:28
mechanical_repairs

Seasoned Pro

Location: leicester

Registered: 10 Jan 2005

Posts: 12,119

Status: Offline

Post #52
smighall wrote:
That's my point Carl, i understand how they work etc, but never taken one apart. And as you know taking apart is the easy part re-assembling is the tricky bit.


As they say assembly is the opposite too removal LOL

It cant be that hard.....Can it?
Carl

________________________________________

C.G.Cars of Leicester, Peugeot/Citroen/Renault specialist Tel: 01162 624498/07799 405184 WWW.CGCARSLEICESTER.CO.UK
36 narborough road south, Leicester LE3 2fn

MOT station now open, tests £35 with a free retest.
Recovery available with a recovery unit, for those not so local jobs

Also offer the loan of a free courtesy car 306 dturbo
Posted 16th Jul 2008 at 06:31
smighall

Smeg-all

Location: b*tching and Whinging

Registered: 03 Mar 2005

Posts: 10,012

Status: Offline

Post #53
That's the theory but even still Laugh

Clearences etc etc

________________________________________

Meh

Seat Leon Cupra FR / 306 GTI6 / Breaking 205 GTI6 / Caterham 7 / Mercedes Sprinter 311CDI LWB

Sold: Fisher Fury - Laguna DCI Estate - P1 306 XSI - E30 BMW 325i Baur Convertible - Daihatsu Fourtack - Suzuki GSXR600 - 205 Rallye
Posted 16th Jul 2008 at 06:33
dr-evil

Senior User

Location: Crewe

Registered: 20 Oct 2006

Posts: 901

Status: Offline

Post #54
One of our first practicals at ag college was to strip out a massey fungus box - i was collared for being 'clever' - laid it out on the bench how it come out so our tutor mixed it all up LOL But striping the clutch packed ford boxes was a drop in the deep end - so many bits its untrue Crazy

Still haven't stripped a car gearbox mind LOL

Pugs lookin sweet by the way

________________________________________

Cad Monkey will work for chocolate biscuits....I'm not kidding
Posted 17th Jul 2008 at 08:33
pugjim

Seasoned Pro

Location: Sheffield

Registered: 11 Mar 2007

Posts: 1,380

Status: Offline

Post #55
smighall wrote:
Put a 1.6 BE3 box on it Carl....it'll top out at 135mph but i'm sure that isn't an issue.


I would go for a 1.6 gti box too. A 1.9 box just isnt suited to a 16v engine at all and a mi16 box seems a little long winded to me unless your planning on doing loads of motorway miles in it. If you using for road only and not planning on going to any tracks with it then your probably not on a bad idea using the vts box but personally i would go 1.6 gti box.
Posted 18th Jul 2008 at 03:55
platty30

Newbie

Location: Gatwick, Surrey

Registered: 21 Jul 2008

Posts: 13

Status: Offline

Post #56
looking awesome....

A L reg Miami Blue 205.....how jealous am I!

Im just starting a similar project, so expect me

to be keeping a very close eye on this thread.

Keep up the good work Thumbs up

________________________________________

Project Status: Stripping the Xsara VTS
Posted 21st Jul 2008 at 04:11
SteviePut

Seasoned Pro

Location: Down south

Registered: 20 Oct 2005

Posts: 13,632

Status: Offline

Post #57
Is that box out of my old shed Carl? If so try adding another 25k to that ~100K milesWhistle

________________________________________

My old man wrote me a letter from prison once. It said if you don't want to end up in here, stay away from crime, women and drugs. Trouble is, that don't leave you much else to do, does it?
Posted 21st Jul 2008 at 05:58
mechanical_repairs

Seasoned Pro

Location: leicester

Registered: 10 Jan 2005

Posts: 12,119

Status: Offline

Post #58
quote:
[quote=\"SteviePut\"]Is that box out of my old shed Carl? If so try adding another 25k to that ~100K milesWhistle


Yes thats the one.

Carl

________________________________________

C.G.Cars of Leicester, Peugeot/Citroen/Renault specialist Tel: 01162 624498/07799 405184 WWW.CGCARSLEICESTER.CO.UK
36 narborough road south, Leicester LE3 2fn

MOT station now open, tests £35 with a free retest.
Recovery available with a recovery unit, for those not so local jobs

Also offer the loan of a free courtesy car 306 dturbo
Posted 23rd Jul 2008 at 02:04
mechanical_repairs

Seasoned Pro

Location: leicester

Registered: 10 Jan 2005

Posts: 12,119

Status: Offline

Post #59
Not really done a great deal more to this project at the minute as i am waiting for various parts to arrive.

Although i did receive a fly wheel and a few bits back from the powder coaters, manganed to fit all the pullies, new water pump etc and fit my modified engine block bracket for the engine mount.

A few teasers, starting to look very pretty-




Heres the bracket i modified with a rather large stil saw, cut the brackets off for the power steering pump, a bit the same way you would if you were fitting the supercharger kit, once this was done i sent the bracket away to be powder coated (its an addiction i tell youLOL)

Obviously you dont cut the brackets off if you car is equipt with pas, mine isnt.





Just waiting for the gear box casing to come back from the powder coaters then the engine and box are ready to be mated back to the engine bay.

Once the engine is sat in the bay i have another sump that has been........ yes wait for it..... powder coated LOL Not fitted that yet as i fear it would get mangled as the engine is slid along the floor whilst fitting it.

Still undecided as to whether i should have the bay re painted as in some places there is the odd mark/scratch and dare i say it some surface rustAngry

Carl

________________________________________

C.G.Cars of Leicester, Peugeot/Citroen/Renault specialist Tel: 01162 624498/07799 405184 WWW.CGCARSLEICESTER.CO.UK
36 narborough road south, Leicester LE3 2fn

MOT station now open, tests £35 with a free retest.
Recovery available with a recovery unit, for those not so local jobs

Also offer the loan of a free courtesy car 306 dturbo
Posted 25th Jul 2008 at 01:21
petegti6

Seasoned Pro

Location: Solihull & Market Harborough

Registered: 09 May 2006

Posts: 12,046

Status: Offline

Post #60
Nice flywheel Razz

That ALL looks SCHWEEEET! Big grin

I remember stripping a 5 speed ZF auto box when i started at Jag, f*ck knows what goes on in there, theres about 60 clutch plates LOL Crazy

________________________________________

Cress87 wrote:
This place is getting beyond a joke. There's been an enormous influx of bellends signing up recently


Team 205 1.9 GTi

Team: Hmm™
Posted 25th Jul 2008 at 01:21
pugjim

Seasoned Pro

Location: Sheffield

Registered: 11 Mar 2007

Posts: 1,380

Status: Offline

Post #61
Theres a 2.0 MI16/s16 top mount what is ideal for your situation, used together with a 2.0 8v alternator bracket and tensioner. This setup is more lightweight and leaves more room round the inlet manifold so makes getting to the starter motor and other jobs like that easier in the future. Saying that tho the last gti6 engine i put in a 205 i did the same as you and just cut the pas bracket off.

You will also find that when you come to plumbing in the coolant system it will be nothing like the original 205 setup, mainly the hoses from the heater matrix and expansion tank will all have to change. Ive seen a lot of people using various t-pieces and hoses which i think looks a little un-tidy. Best thing to do is get a the housing from the back of the block from an s16 engine which will make use of your original heater matrix and expansion tank hoses Thumbs up
Posted 25th Jul 2008 at 20:24
damien

Seasoned Pro

Location: kent

Registered: 27 May 2005

Posts: 5,853

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Post #62
bloody hell how quick is this moving along....

cant wait to see the finished pics as i need some ideas to clean up the engine bay
Posted 26th Jul 2008 at 00:20
mechanical_repairs

Seasoned Pro

Location: leicester

Registered: 10 Jan 2005

Posts: 12,119

Status: Offline

Post #63
damien wrote:
bloody hell how quick is this moving along....

cant wait to see the finished pics as i need some ideas to clean up the engine bay



You and me both, i cant wait to see how fast they feel with the six lump in thereLOL

Carl

________________________________________

C.G.Cars of Leicester, Peugeot/Citroen/Renault specialist Tel: 01162 624498/07799 405184 WWW.CGCARSLEICESTER.CO.UK
36 narborough road south, Leicester LE3 2fn

MOT station now open, tests £35 with a free retest.
Recovery available with a recovery unit, for those not so local jobs

Also offer the loan of a free courtesy car 306 dturbo
Posted 26th Jul 2008 at 00:23
gtisid

Seasoned Pro

Location: chelmsford

Registered: 22 Mar 2003

Posts: 4,992

Status: Offline

Post #64
how does all this powder coated stuff cope with the heat? i had a manifold on my engine originally and it seemed ok but cam covers i know are hot very hot as i nearly burnt the tip of my finger off . i am thinking of having my brakes done soon but am worried that as they are iron even if they are cleaned will eventually rust under the powder and make the stuff lift off. would imagine it is a lot easier to keep clean than polished metal i do hate having to polish my engine to keep it shiney. with all this work carl i think you will kick yourself if you dont finish the engine bay to the same standard as the rest of the car. do love the blue in the 205 i only really noticed them years back when they started doing them in this colour as i was a ford nut then who drove a fiat???
hurry up with this carl as it is the most interesting thread i have read in ages

________________________________________

pugless
Phase 1 GTI 6 1996-1997
Subaru Impreza GB270 2007-2008
rare spiderman comics
same day international courier
Posted 26th Jul 2008 at 04:03
maddriver9

Regular

Location: nr leek

Registered: 12 Mar 2008

Posts: 341

Status: Offline

Post #65
i thinking off running my 205 gti6 on a 1.6 gear box but i spoted the crank senser in the 6 box but 1.6 boxs dont have them so it wouldnt run. i was wondering how to get round this as it seems like loads of you have done it before

________________________________________

178bhp 205gti6
¼ mile in 14.2
Posted 27th Jul 2008 at 01:50
pugjim

Seasoned Pro

Location: Sheffield

Registered: 11 Mar 2007

Posts: 1,380

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Post #66
maddriver9 wrote:
i thinking off running my 205 gti6 on a 1.6 gear box but i spoted the crank senser in the 6 box but 1.6 boxs dont have them so it wouldnt run. i was wondering how to get round this as it seems like loads of you have done it before


Nearly every 205 GTi (especailly ph 1.5-2) will have the hole in the gearbox for a std crank sensor. Thumbs up
Posted 27th Jul 2008 at 14:01
maxi

Junior User

Location: Burgess Hill

Registered: 25 May 2005

Posts: 82

Status: Offline

Post #67
Early BE1 boxes dont have the crank sensor hole and to be honest are avoidable at all cost anyway as they have a stupid clutch arm setup too.

Project is looking really good!

Maxi

________________________________________

205 GTi6- 250BHP
205 GTi6- STD
306 GTi6- Black Phase 3
Posted 27th Jul 2008 at 15:14
maddriver9

Regular

Location: nr leek

Registered: 12 Mar 2008

Posts: 341

Status: Offline

Post #68
sound, i take it that the fly wheel stays on the and a mi16 clutch is used

________________________________________

178bhp 205gti6
¼ mile in 14.2
Posted 27th Jul 2008 at 19:26
pugjim

Seasoned Pro

Location: Sheffield

Registered: 11 Mar 2007

Posts: 1,380

Status: Offline

Post #69
maddriver9 wrote:
sound, i take it that the fly wheel stays on the and a mi16 clutch is used


Yep gti6 flywheel and an mi16 clucth work perfect.
Posted 27th Jul 2008 at 22:00
MCH_GTi6

formerly mch

Location: Hayle

Registered: 09 Sep 2005

Posts: 2,446

Status: Offline

Post #70
how are you dealing with the issue of the cam covers being close/striking the master cylinder?

hoping to be doing a similar conversion to this in the near future...

________________________________________

Team Moonstone� Ph3 GTI6
Team Rallye
Posted 28th Jul 2008 at 19:31
mechanical_repairs

Seasoned Pro

Location: leicester

Registered: 10 Jan 2005

Posts: 12,119

Status: Offline

Post #71
On the ones i see its not the cam covers that sit close its the cambelt cover, some people just cut a small section out but i have heard of a mounting that makes the engine sit lower, i think its an escort mkII mounting or something.

I will look into it a it more when i come to mount mine.

Carl

________________________________________

C.G.Cars of Leicester, Peugeot/Citroen/Renault specialist Tel: 01162 624498/07799 405184 WWW.CGCARSLEICESTER.CO.UK
36 narborough road south, Leicester LE3 2fn

MOT station now open, tests £35 with a free retest.
Recovery available with a recovery unit, for those not so local jobs

Also offer the loan of a free courtesy car 306 dturbo
Posted 29th Jul 2008 at 00:21
pugjim

Seasoned Pro

Location: Sheffield

Registered: 11 Mar 2007

Posts: 1,380

Status: Offline

Post #72
mechanical_repairs wrote:
On the ones i see its not the cam covers that sit close its the cambelt cover, some people just cut a small section out but i have heard of a mounting that makes the engine sit lower, i think its an escort mkII mounting or something.

I will look into it a it more when i come to mount mine.

Carl



The room you have seems to differ with every 205. Personally I wouldnt use anything but the std 205 mounts (group a ones). Using an extended bottom mount and lower top mount can cause other problems like premature driveshaft failure as the shafts will be at a different angle. also the gti6 sump sits lower than the 8v sump on std mounts so lowering the engine down makes it even closer to speedramps Whistle

There is also quite a bit of movement on the gearbox mount so if you slacken off the 2 13mm nuts holding it to the battery tray you can get a nice long bar in there and prize it over so theres more room for the master cylinder. Big grin

Hope you get it in soon so you can fel the difference in a 205 Thumbs up
Posted 29th Jul 2008 at 01:08
platty30

Newbie

Location: Gatwick, Surrey

Registered: 21 Jul 2008

Posts: 13

Status: Offline

Post #73
pugjim wrote:

Hope you get it in soon so you can fel the difference in a 205 Thumbs up


Me too.

But more so I can see what problems you encounter so I can avoid them on mineLOL

Good work though, gotta love an engine you can eat your dinner off!

________________________________________

Project Status: Stripping the Xsara VTS
Posted 29th Jul 2008 at 01:21
MCH_GTi6

formerly mch

Location: Hayle

Registered: 09 Sep 2005

Posts: 2,446

Status: Offline

Post #74
mechanical_repairs wrote:
On the ones i see its not the cam covers that sit close its the cambelt cover, some people just cut a small section out but i have heard of a mounting that makes the engine sit lower

Carl



Blush thats what I meant... oops

________________________________________

Team Moonstone� Ph3 GTI6
Team Rallye
Posted 29th Jul 2008 at 02:13
maddriver9

Regular

Location: nr leek

Registered: 12 Mar 2008

Posts: 341

Status: Offline

Post #75
do you need to bolt the lamba sense in the 205 down pipe to run the gti6 properly

________________________________________

178bhp 205gti6
¼ mile in 14.2
Posted 29th Jul 2008 at 03:56

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