[trackday_prep] Paul's Gti6

[Paul_13 212 1 Cars]

Right more sh!t luck.

 

Had the inlet pulley snap on me luckily I didn't bend any valves. Had the head rebuilt, new belt kit etc.

Now I double and triple checked everything, got all the torque settings and made sure everything was spot on.

 

Now the bolt holding the idle pulley on cam belt has snapped, I managed to stop the car before it bent any valves and whip the cover off.

The belt has chewed itself a bit and when I saw the idle pulley sitting on the p!ss I prodded it and it sheared off. Luckily the cams feel in a safe position and didnt snap back.

 

Now I've got to remove the end of the bolt in the block and get a new belt. But the cams are no where near the timing holes, and I don't want bend/ damage anything.

 

Going down the motor factors to have a right go and get the belt for free at the least I hope.

I have used this belt kit before many a times with no problems, why should this bolt fail? It's a contitech kit which has been recommended to me by somebody on the 6 forum.

I haven't over tightened it, the belt wasn't majorly tight.

 

I'm currently on the way back from Leeds in the front of an AA van. LIVID!

 

I'll post up pics tomorrow, its a bit of a mess in there.

[welshpug 1,627]

did you use a new bolt?

[Paul_13 212 1 Cars]

Yep one that came with the kit

[welshpug 1,627]

bugger.

 

was the bolt and pulley the same type as the old one?

 

I noticed that Peugeot (and Dayco-INA/SKF aftermarket as a result) had altered the design of the bearing and required a shorter bolt to be used, the one supplied was 1mm too long.

[Paul_13 212 1 Cars]

Yes same design as the last.

Could sound daft but is the bolt supposed to have a smooth shank on it or thread the whole down?

[welshpug 1,627]

the original was a shanked Bolt not a Capscrew I believe.

[Paul_13 212 1 Cars]

Hmmm.. why have they supplied with that bolt if that's the case?

I'll pop down in the morning and have a look through the other box there

[Paul_13 212 1 Cars]

Update time:

 

Got fed up of the CF bonnet flapping around everywhere and ripping my lamp panels to shreds, I now have a normal Auto bonnet which ive painted matte black.

Painted grille to go with bonnet:

 

Change the rear buffer to a standard item and re spaced the other mounts, so they do not press on the engine mount as much. Hopefully this sorts out the vibration problem that was driving me crazy(er)

^Has any body done the same, or am I going to have to change the other 2 to stop the vibrations?

 

Got the rear tyres swapped over onto my GTI6 steelies, due a paint job.

 

New bits

 

More new bits; track arms, wishbones (cheers Miles) and 266mm brakes (cheers Anthony). Need a scrub, put them on the floor to bleed them made it rather easy!

 

Bent it down slightly to clear the exhaust springs.

 

Extended the heatshield as the rubber boot was being scorched. Vw's suffer from this problem and set on fire... f*ck that.

 

Picture of my untidy engine bay

 

Gaitors fitted

Edited June 4, 2011 by Paul_13

[Paul_13 212 1 Cars]

Started piping up cold air feed using the pipe I got off Cheesegrater (cheers mate!)

 

Moved the engine loom from behind the exhaust to behind the coolant tank

From here

To here

 

Blanked off hole

 

Rebuild head and polished crank awaiting return of the engine block...

 

State of the back of the car

[SurGie 54]

Hmmm.. why have they supplied with that bolt if that's the case?

I'll pop down in the morning and have a look through the other box there

 

 

Ive just had a quick look inside my Dayco belt kit and my bolts are missing, this kit was bought December last year.

 

Are these belt kits supposed to have the bolts ?

 

I think ill be going down to see the dealer and get it swapped ?

 

Cheers

[Paul_13 212 1 Cars]

I've got loads of these bolts spare (new) which are the correct grade, send me your address mate and i'll get one shipped off to you. Saves you the hassle.

 

The contitech kits do contain the bolts

Edited June 4, 2011 by Paul_13

[Spiky 37]

dude you had some seriously bad luck with this car..

 

 

 

great to see you still going on,

 

did you sell the carbon bonnet?

[Paul_13 212 1 Cars]

No didn't sell it in the end just made a few things out of it before I cut it up for the bin, it was doing my head in and ruined the head lamp panels on the car.

 

I found a centre cap off a GTI wheel and it fitted my steelies But will it fit when the wheel is on the car? Will be fitting them today/tomorrow after I finish painting.

 

 

Pic of the new bonnet fitted and lined up, much better

 

 

Here's a few pictures of my mates car with his new exhaust fitted

 

I love this car, it's a toyota levin BZR (1.6 20v on individual throttle bodies, super strut suspension and a LSD as standard.

[Alan_M 66 1 Cars]

No didn't sell it in the end just made a few things out of it before I cut it up for the bin, it was doing my head in and ruined the head lamp panels on the car.

 

I found a centre cap off a GTI wheel and it fitted my steelies But will it fit when the wheel is on the car? Will be fitting them today/tomorrow after I finish painting.

 

 

Pic of the new bonnet fitted and lined up, much better

 

 

Here's a few pictures of my mates car with his new exhaust fitted

 

I love this car, it's a toyota levin BZR (1.6 20v on individual throttle bodies, super strut suspension and a LSD as standard.

 

Is the Toyata local? Think I saw it at the Lower Earley BP.

[Paul_13 212 1 Cars]

He lives round the corner from you up beech lane mate

[Paul_13 212 1 Cars]

Liking the new wheels. Going to weigh one tomorrow. See if I am saving anything, over the heavy casting 1.9 wheels (SMR's)

 

 

Sanded down and painted the rear badges, just waiting for the mastic to dry out.

 

Polybushed the 309 wishbones on the diesel yesterday, managed to nearly cut my finger off with the hacksaw. F*ck me that hurt, blood everywhere.

 

Established that 13" wheels do not fit on 1.9 brakes.

 

Never buy firstline parts, track rod ends lasted 2000miles and they're fudged!

Edited June 14, 2011 by Paul_13

[welshpug 1,627]

Liking the new wheels. Going to weigh one tomorrow. See if I am saving anything, over the heavy casting 1.9 wheels (SMR's)

 

sod all

[Paul_13 212 1 Cars]

Update:

 

Ordered a load of bits from Peugeot earlier, the bloke was astounded with the bombardment of part numbers which were all correct

 

051378 - Oil pump sprocket (GTI6)

053740 - Flywheel bolts " (10 min. so have some spares PM me if your interested)

697606 - Woodruff keys " (8 Spare)

051492 - Rubber seal " (9 Spare)

 

103310 - Oil pump chain (GTI6)

973641 - BV Gearbox oil (listed as a different number on their system)

179875 - Exhaust fixing kit

1920W9 - Crank sensor

 

0209Z2 - Headgasket (GTI6)

0349G1 - Inlet gasket "

156621 - Lion badge on inlet "

130778 - Metal water pipe in arch

 

Sorry no prices, code references will come in useful to someone.

 

 

Also picked up block yesterday

Just to drop the crank in now with the bearings etc. The bottom end bearings I am using are Glyco, at a bargain price!

Also have a lightened pulley almost in my possession, just to buy the flywheel next.

 

I am taking my time with everything, painting bits and finally have a garage I can use so, I can take my time

 

 

Fingers crossed the engine stand will be found by the courier sometime this week, somehow they managed to lose it !

 

Also a pic of the diesel with 1.6gti wheels on, had to shave a bit of the caliper off to fit these on

 

Now has GTI seats, carpet, dash,wheel etc just need to get rid of those ghastly beige door cards and rear quater trims.

Need to replace the top mount rubbers as I swear theres no rubber left in one of them.

[Paul_13 212 1 Cars]

Serious work has begun!

 

 

 

 

 

 

I've got the boots to go on, borrowed the diesel boots

[Tesstuff 222]

Nice progress Paul

 

But still seems a lot of trouble to have a 'gay' and 'slow' car lol

[Paul_13 212 1 Cars]

Sod off you queer

 

It's the amount of work involved with a V6 that puts me off mate. Plus it's all there already for the 6 engine. Loom/ecu/Xsara box etc

 

Going to be supercharging it in the winter hopefully, we'll see who the 'gay boy' then

[GLPoomobile 958]

we'll see who the 'gay boy' then

 

Probably the one who sculpts snow penis'

[Paul_13 212 1 Cars]

Bastard! Was just changing that avatar before someone said that

 

Weren't me who did the sculpting lol, I got a pic of a mate hugging it, funny as

Edited July 16, 2011 by Paul_13

[Tesstuff 222]

Sod off you queer

 

It's the amount of work involved with a V6 that puts me off mate. Plus it's all there already for the 6 engine. Loom/ecu/Xsara box etc

 

Going to be supercharging it in the winter hopefully, we'll see who the 'gay boy' then

 

 

Hmmm, supercharged you say

 

You 'might' keep up then mate

 

Be fun finding out

[Anthony 1,000]

Given the problems you have keeping a standard engine in one piece Paul, are you sure adding a blower to it is a good idea?

 

Looks like it's coming along nicely though, and fingers crossed you'll have slightly more luck with this engine that you've had previously!