[engine_work] Sleeper 1.6 Project

[2052006 10]

I've had GKN (1.9 ones with the VTS inner bit on the n/s) on mine for the past 4 months/1000 miles or so with no problems, including a track day, though I've not got a fancy diff on it. Hope those xsara struts do the job, I'll be interested to hear what sort of difference they make.

[Galifrey 1]

Well the new shafts are on, clonking is reduced but still some from the diff at low speed which is worse the slower you go, so may have the solution for that already

 

Miles said the shafts were original (from the date stamps, genuine pug made in 1988), so they had a good run at 116,000 miles.

 

Xsara VTS struts are on, whole car feels very planted, am still a bit careful but had a good blast down some lanes on the way home, and nothing seems to upset the front

 

Really starting to get used to the engine and ratios now so can make the most of it, it is fearsome on the corner exits, gives a little twitch as one wheel loses grip then pow, grip pull pull pull.... and the weather has been well sh*tty today, snow and everything!

 

Miles seems to have a special tool for everything, guess thats what you get when you go to someone who specialises in 205's.

[Galifrey 1]

Today I have mostly been blasting around Bristol (in a very irresponsible way), however, the big grommet around the steering column has fallen out of my bulkhead grrr

 

Have been discussing the "sticktion" in my steering with Miles, it was there pre conversion, but seems worse now (and agravated by the extreme steering ratio) so we are going to try some mods in the new year to improve it as it makes small adjustments of the steering a bit annoying.

 

Fitted some Halfrauds "Extreme Brilliance" (+90%) H4 bulbs today, and they are much better than the bulbs that were in there, I feel more confident in the dark now... I was tempted to fit the rally spec bulbs, but knowing my luck I would get pulled for them

[Gregg 0]

Fitted some Halfrauds "Extreme Brilliance" (+90%) H4 bulbs today, and they are much better than the bulbs that were in there, I feel more confident in the dark now... I was tempted to fit the rally spec bulbs, but knowing my luck I would get pulled for them

 

I've not been impressed with the 'Rally' bulbs (80/100W), never seemed much brighter than standard and still a bit yellow. Much prefer the ultra blue, 80/100w so not strictly legal, but they give a decent blue/white light that's not too blue! (Nice and cheap with a trade card as well )

 

I've been following your build and it's giving me bad ideas, I've had a 306 GTi-6, 309 GTi and 205 XS but never a 205 GTi, so now I want to combine them all and have a 205 GTi-6 Not sure the other half will let me buy any more cars just yet though

Edited December 18, 2009 by Gregg

[Galifrey 1]

I've not been impressed with the 'Rally' bulbs (80/100W), never seemed much brighter than standard and still a bit yellow. Much prefer the ultra blue, 80/100w so not strictly legal, but they give a decent blue/white light that's not too blue! (Nice and cheap with a trade card as well )

 

I've been following your build and it's giving me bad ideas, I've had a 306 GTi-6, 309 GTi and 205 XS but never a 205 GTi, so now I want to combine them all and have a 205 GTi-6 Not sure the other half will let me buy any more cars just yet though

 

That's good to know you should definitely consider the conversion, it's a lot of fun to drive

[jackherer 543]

Today I have mostly been blasting around Bristol (in a very irresponsible way), however, the big grommet around the steering column has fallen out of my bulkhead grrr

 

Have been discussing the "sticktion" in my steering with Miles, it was there pre conversion, but seems worse now (and agravated by the extreme steering ratio) so we are going to try some mods in the new year to improve it as it makes small adjustments of the steering a bit annoying.

 

I had to trim the grommet where the lower column goes through when I fitted a Xsara rack as the column is slightly thicker. It took me a couple of goes to get it right IIRC.

 

If there is a problem with your steering that is still present with a different rack and lower column surely it must be the upper column causing it?

[Galifrey 1]

If there is a problem with your steering that is still present with a different rack and lower column surely it must be the upper column causing it?

 

Yes I agree mate, there must be some sticktion in the upper column, I am set to investigate when I can feel my fingers for longer than 5 minutes outdoors!

 

The steering does not get noticeably lighter at high speed, which is weird, what makes me think upper column, is that the power assistance doesnt really happen until there is some steering input, once moving the steering its not to bad, its just that initial sticktion.

Edited December 18, 2009 by Galifrey

[welshpug 1,622]

I think Maxi had a fairly similar issue recently, the steering would become very stiff, I believe he solved it with a replacement upper column

[Galifrey 1]

I think Maxi had a fairly similar issue recently, the steering would become very stiff, I believe he solved it with a replacement upper column

 

Thanks Mei, useful info that further confirms my suspicions

[Miles 331 1 Cars]

At least the Coloum is a easy change, Shame the snow didn;t come up your way as it would have been a good test for the Diff !!

[Galifrey 1]

Shame the snow didn;t come up your way as it would have been a good test for the Diff !!

 

Monday apparently

 

[Galifrey 1]

Monday apparently

 

 

Diff tested

 

Spent today trying to re-condition some window switch brackets, but despite sanding off the grime, dishwashing, soaking in bleach and treating with plasticare, I cannot get rid of the smell of stale sweat

 

Knowing the result that will give come the warm weather, going to have to source some more.

[Alastairh 47]

Im not sure if i missed it, but what springs did you choose in the end to match the xsara shocks, after we were talking about it?

 

Al

[Galifrey 1]

Im not sure if i missed it, but what springs did you choose in the end to match the xsara shocks, after we were talking about it?

 

Al

 

Got the stock springs at the moment, going to see how they pan out, they dont seem too bad, may just drop the back to match.

[Galifrey 1]

Car has suddenly become a bitch to start.

 

Crank it over and over, no sign of firing, all relays fine, got spark. Leave it a while, go back, it kicks a few times, the splutters to life and runs sweet as a nut.

 

Any ideas? Was thinking might be a temp sensor or something (ECU)

[dcc 855]

check the blue connector on the cam pulley side of the head. mine had something liek this happen. the plug had not been reconnected.

[Galifrey 1]

check the blue connector on the cam pulley side of the head. mine had something liek this happen. the plug had not been reconnected.

 

Already done, thanks for the suggestion tho, have checked all connections are there, I suspect a sensor somewhere is failing tho!

[Galifrey 1]

Checked the plugs, no problem there, all look a nice tan colour, sparking fine.

 

Its a mystery so far.

[kyepan 291]

fuel pump going?, you can bridge the thick wires on the relay to check.

 

i had a similar problem and it was fuel pressure related.

 

J

[Galifrey 1]

fuel pump going?, you can bridge the thick wires on the relay to check.

 

i had a similar problem and it was fuel pressure related.

 

J

 

Yup fuel pump is running, relay working, can hear fuel pump kick on, once it starts it runs fine, just a bitch to start

[Paul_13 212 1 Cars]

Try and check the fuel pressure somehow, I've had this problem and so has J (kyepan).

 

Pretty sure it was the return valve, this maintains the pressure and can fail intermittently.

I've had the same problem where it will/might not start again when warm and out of no-where it'll jump to life once the return valve starts working again. I find a good thump helps

 

Put a pressure guage on the return line somewhere?

 

I'm 80% sure this will be the pump not maintaining pressure, even though you can hear it doesn't mean it's working properly.

 

I changed the pump and never had a problem since.

Edited January 27, 2010 by Paul_13

[Miles 331 1 Cars]

A way to check the pressure is just give the engine a fwe clicks on the starter before starting it, This should get the pressure up,

Mind the 205 I drove back today had a failed pressure Reg and the engine just didn;t want to drive on all 4,

Temp sensor OK?

[Galifrey 1]

Temp sensor OK?

 

 

This is my main suspect at the moment. Squirted some carb cleaner into the small air filter and it started 2nd turn today, but wouldnt rev properly until it was warm, a sure sign it is lean when cold iirc

 

Its the lower one on the block of 3 on the thermostat housing for the ecu temp sensor I believe.

 

Checked the plugs and they are perfect, light tan electrode, slight soot on the metal, so it is fine when warm, and goes like stink.

[Paul_13 212 1 Cars]

Might help

 

The ecu temp sensor bit is a fair bit down the page.

 

It's the third one down on the thermostat housing

Edited January 28, 2010 by Paul_13

[Galifrey 1]

Removed and refitted the bottom plug of the 3 a few times, and then tried it, and it fired first time and revved cleanly (as good as ever).

 

Must be the ECU temp sensor plug was a bit sh1tty!

 

Thanks for that link Paul, have book marked it!

Edited January 28, 2010 by Galifrey