[trackday_prep] Paul's Gti6

[cheesegrater 43 1 Cars]

I'm more concerned by this...

[Paul_13 212 1 Cars]

That was when I was working at Brighton lad I was working with had the pass card for the door. It's one of their mascot outfits lol.

 

Fitted the front leathers to the GRD earlier Front seat bolts on 5 door subframes are a bastard!

Edited February 10, 2012 by Paul_13

[allye 530 3 Cars]

I bloody hate those front bolts! You can't fit a ratchet torx in there so end up using torx key and turning those super long bolts 1/3 of a turn at a time

[Paul_13 212 1 Cars]

I was out doing them for an hour! I cheated in the end and used to shorter bolts that were holding the subframes to the old seat Still a bastard of a job!

[cheesegrater 43 1 Cars]

I was out doing them for an hour! I cheated in the end and used to shorter bolts that were holding the subframes to the old seat Still a bastard of a job!

You need that teng tool I have for them!

[Paul_13 212 1 Cars]

I was actually thinking of driving round to my Dad's with no seat to borrow the same tool

[Paul_13 212 1 Cars]

Did some more

 

Xsara crownwheel with 205 diff in place

 

 

Diff cover

 

 

VSS sensor modified as it fouled on the gearbox, couldn't get the plug on

 

 

 

Gearbox done

 

 

Photo for reference

 

 

Engine bay on the weekend

 

Edited February 14, 2012 by Paul_13

[Paul_13 212 1 Cars]

Changed the top mounts for OE items (cheers Cheesegrater for picking those up )

 

 

Wiring routed through into the cabin

 

 

How it looks now

 

 

And removed the grp a fork bushe, to be replaced with a brand new OE bushe

 

[Paul_13 212 1 Cars]

Bit more

 

 

Where the engine management light would be.

 

 

Wire on the car side of the loom 74a. It works now

 

 

What the 6 pin plug looks like

 

 

Inlet on (for the 100th time)

 

 

Moved the air filter into the engine bay, see if the straighter run to the throttle body makes a difference

 

 

This little bugger was stuck in the air filter

 

 

Moved the shunt box to a more solid mounting that doesn't involve cable ties

 

 

 

Had a real worry earlier... Started it up and it was misfiring like fook. Checked the plugs going to the injectors and coils, all fine!?

Took the spark plug out, again looked normal. Changed the coilpacks about as cylinder 1 wasn't firing and it was exactly the same?!

Checked the earth etc, and was fine.

Changed the ecu over to another I have and it went back to normal!

Changed the ecu again to the old one and it's fixed! Well confused on that one.

 

Also discovered there's a dodgy earth connection on the front end.

 

Jobs for tomorrow:

 

Remove struts and soften shocks.

Fit driveshafts and gearbox oil.

Do up hub nuts

Fit wishbone and new bolts

Tighten up wishbone bolts on the floor

Buy a mini filter from halfords and jubilees

Change harnesses

Fit dash plastics

Bash heatshield so it's not rubbing on exhaust manifold

Bleed coolant

Change indicator

Measure seats

Fit engine fork

Sand off brake pads

Check speedo cable

Find a new fan switch plug

 

Drive

[Miles 331 1 Cars]

Got to post this on here, What did you do on your old box, it was pretty much on it's last legs, , Sun & Planet gears where ready to strip, 5th gear had a tooth missing so you did well,

Also it wasn't a Xsara box, a S16/405 box

[Paul_13 212 1 Cars]

Ahh... I was told it was a low mileage box when I bought it and I helped take it off the Xsara, so they were none the wiser.

That's pissed me off a bit

[cybernck 400 1 Cars]

They knew you were going to destroy it anyway .

[Paul_13 212 1 Cars]

Remove struts and soften shocks.

Fit driveshafts and gearbox oil.

Do up hub nuts

Fit wishbone and new bolts

Tighten up wishbone bolts on the floor

Buy a mini filter from halfords and jubilees

Change harnesses

Fit dash plastics

Bash heatshield so it's not rubbing on exhaust manifold

Bleed coolant

Change indicator

Measure seats

Fit engine fork

Sand off brake pads

Check speedo cable

Find a new fan switch plug

Take rear 6x9's out and put other rear cards in

Fit strut brace

Strip down old beam

Insulate starter wire I cut out! I know i'll forget this

Buy 5.1 brake fluid in the morning

Change wiper blades and source some twin jets.

 

 

Drive

 

Nearly there, ended up sticking the 307 HDI brakes back on so the 266mm setup is for sale.

 

Edited February 17, 2012 by Paul_13

[Paul_13 212 1 Cars]

Remove struts and soften shocks.

Fit driveshafts and gearbox oil.

Do up hub nuts

Fit wishbone and new bolts

Tighten up wishbone bolts on the floor

Buy a mini filter from halfords and jubilees

Change harnesses

Fit dash plastics

Bash heatshield so it's not rubbing on exhaust manifold

Bleed coolant

Change indicator

Measure seats

Fit engine fork

Sand off brake pads

Check speedo cable

Find a new fan switch plug

Take rear 6x9's out and put other rear cards in

Fit strut brace

Strip down old beam

Insulate starter wire I cut out! I know i'll forget this

Buy 5.1 brake fluid in the morning

Change wiper blades and source some twin jets.

 

 

Drive

 

All done with Tom's help today

Just a few bits to do now

[welshpug 1,622]

twin jets are cheap from pug (standard on the later 205 and same part as 306's)

[Paul_13 212 1 Cars]

01

 

6438 71

 

02

WDW WASHER JET

TWIN JETS

 

I found something!

Edited February 18, 2012 by Paul_13

[Paul_13 212 1 Cars]

 

ICV filter fitted

 

 

The autofactor sold me a 309 driveshaft in a 205 box by accident it was bunching up pretty bad and sending vibrations through the car.

 

 

Quickly put a spare inner cv cup in before too much fluid leaked out, saves buying another tub as I have half of one spare

[Tom Fenton 1,525]

If you jack that side of the car right up in the air as high as you can, you can swap that shaft without losing any box oil.

 

I know this as I had to do it outside the guest house in Germany when the useless bastards sold me a "205" short shaft that was too bloody long as well. Sadly it only caused a problem when being driven in anger around the 'ring, when the NSF suspension was compressed.

[Paul_13 212 1 Cars]

Thanks for the tip Tom

[Paul_13 212 1 Cars]

Put the shaft in earlier and fits now

Going to take it for a quick spin tomorrow

[Strictly_Derv 34]

Are you taking this too pick the seats up at the weekend?

[Gman 29]

back from the honeymoon now mate, so if you need any help with anything (not that I know what to do but can hold spanners and s*it), just give me a bell and I'll come over

[Paul_13 212 1 Cars]

^ Cheers Gman

 

Had the MOT on the dieasel today and it passed

Managed to get the door to open, turned out it was the lever on the back of the handle was seized. Bit of WD40 and 5 mins of working it and now it's free

 

Wheel swap

 

 

 

 

Quite like the reversal

 

Also stripped down the 205 beam I have spare, inner bearings were a c*nt to get out! Just got to remove the bushes next done 2 of them just the other half to go.

 

Took the Gti out for a proper drive earlier, annoyingly 4th gear syncro is buggered !

[Anthony 1,000]

FFS - you really don't have any luck do you!

 

4th seems an unusual synchro to be knackered though - normally seems to be 2nd/3rd that get abused.

 

At least the diseasal has a fresh ticket on it though.

[Paul_13 212 1 Cars]

Nope... I'll let you drive it tomorrow if I bring it round, so I know i'm not going mad