Tu Major Service

[stuart_knight6 0]

So, just bought a 205 1.4 XS on a "G" plate. It only has 60,000 miles and in the last 5 years has only done 2000 miles, so is need of a good service. I have bought a lot of stuff that i think it needs doing and from reading through the forum there is clearly some other items as well.

 

So far I have:

 

Head Gasket - Not sure it needs doing but will do it anyway - Comes with lots of seals that I havent worked out what they are for yet

 

Rocker Gasket

 

Anti-freeze

 

Fuel Filter

 

Cam belt + Tensioner

 

Fan belt

 

Valve Stem Seal

 

Thermostat

 

Oil + Filter

 

K + N Filter + Jets

 

Distributor, rotor arm, plugs, leads

 

Exhaust Manifold - Courtesy of Macaroni

 

Any other items that I should be looking at. Brakes are the next item that I will be working on with an upgrade to HDi or Gti6 parts.

 

Thanks,

 

Stu

[bren_1.3 1]

save your money on the brakes, your not stopping an Mi16. get some mintex pads or ferodo's.

 

doubt there would be much point in changing the head gasket? unless its on its way out?

 

the rest of the seals with that head gasket kit are probably the cam seal and valve stem seals, plus others i cant think of.

[GazRallye 0]

Another option with the brakes is discs form a 1.9 gti and calipers from a 1.6 gti, there the same size discs but ventilated

[macaroni 17 1 Cars]

Don't bother with the head gasket or valve stem seals unless you need to, you masochist! Is it using oil/water?

 

I upgraded mine to 306dt brakes and I love it.

 

While the cambelt is off, you might want to think about the water pump, especially if it has sat about for so long.

[stuart_knight6 0]

OK, Think your right about head gasket. Havent noticed it using oil or water, just wanted it done as a safety precaution.

 

Not sure which brakes to go for as I only have 13" wheels at the moment, and dont really want to change them. Will the Gti Calipers and brakes fit under them?

 

Will order a water pump now.

 

Cheers

[stuart_knight6 0]

Its an 1989. Do i need an 18 tooth or 20 tooth waterpump?

 

Trying to order now from GSF.

[macaroni 17 1 Cars]

Sorry I can't help there. I have had mine out, but I didn't count the teeth.

 

Having said that about the water pump, mine has done over 160K miles on the original water pump and it is perfect.

[Jrod 7]

Gearbox oil is probally worth chaging aswell.

Edited February 12, 2007 by Jrod

[stuart_knight6 0]

Thanks for the advice guys. Didnt bother with the water pump in the end.

 

So, will the 1.6 calipers and 1.9 dics fit under my 13" steel wheels as they have brand new tyres on and i wouldnt want to bin them?

 

Will update you all when it is up and running, fingers croseed, tonight.

 

Cheers

[Rippthrough 98]

Thanks for the advice guys. Didnt bother with the water pump in the end.

 

So, will the 1.6 calipers and 1.9 dics fit under my 13" steel wheels as they have brand new tyres on and i wouldnt want to bin them?

 

Will update you all when it is up and running, fingers croseed, tonight.

 

Cheers

 

 

Should do, only 247mm.

[Jrod 7]

The 1.6 calipers won't fit under XS wheels.

 

Well on mine they wouldnt, the caliper was to wide and hit the inside of the wheel.

[bren_1.3 1]

1.6 calipers go under my 13 inch pug sport group A rims no problem!

[stuart_knight6 0]

I only have the standard rims though. Might just bite the bullet and buy the discs and calipers and fingers crossed they fit, if not then will go to scrapyard and pick up some 14" steels.

[Sandy 191]

1.9 callipers (correct english spelling apparently) need a bit ground off the edges to go under 205 Rallye ET28 steels.

[stuart_knight6 0]

So, should I go with 1.6 or 1.9 calipers? with 1.9 discs?

[Jrod 7]

Up to you but they won't fit under XS wheels.

[stuart_knight6 0]

Right, got it all back together including a new cambelt and tensioner. Started it up and it runs first time, only trouble is that it makes a ticking noise and when watching the cambelt it looks as though it is going to slip off the side of the cam pulley.

 

What could possible be wrong? I have set the tension so that on the cambelts longest run it can rotate 90 degrees/quarter of a turn. Could it be too tight? But would this cause the ticking noise? I havent adjusted the valve clearances at all, so I cant work out what is different from before.

 

I didnt remove the head either.

 

Please help...

[GazRallye 0]

The cambelt does sit pretty close to the edge of the cam pulley, so i shouldn't worry too much about that so long as its tensioned properly... which by the sounds of things you have, if it was too tight you'd hear a pretty loud whirring noise.

 

not too sure on the ticking noise, is it louder than before? could just be that the valve clearances need adjusting, that should quiet it down a little, but these engines do have a very tappety sound when ticking over.

[stuart_knight6 0]

The cambelt actually hangs off the side of the cam pulley, surely that cant be right. I cant find anyway of keeping it overhanging.

 

It sounds more tappety than before I serviced it. Maybe the valve clearances do need doing but why would it get noiser during a service.

[bren_1.3 1]

The cambelt actually hangs off the side of the cam pulley, surely that cant be right. I cant find anyway of keeping it overhanging.

 

your right, that isnt right.

 

pull the belt off and do it again. i doubt youve got the wrong belt though. they either fit or they dont.

[stuart_knight6 0]

I had another look at this last night and it looks as th ough the tensioner i fitted is slighty off centre. It doesnt look like the face the belt sits on is in line with the rest of the pulleys so when it rotates it is forcing the belt off.

 

The spindle that the tensioner sits on, can it be replaced, if so, how and does anyone have a new one or shall i just try and bend it back a little?

[stuart_knight6 0]

Can any one help with this...starting to wish i had just taken the chance and not touched the tensioner.

[bren_1.3 1]

the stud the tensioner slots onto is bent?

 

it just screws in *i think* (i can check tonight on my spare block), but you'll have to use the two nut trick to get it out if you want to replace it.

 

id be wary of trying to bend the bugger back into shape. dont want too weaken it further.

[stuart_knight6 0]

I cant be sure that it is bent as i havent got the tensioner off, but the tensioner face doesnt look perpendicular (90 degrees) to the block which would explain why the belt looks like it is going to fall off.

 

Thanks for the help, just want to get the car back on the road and get used to it.

[bren_1.3 1]

tis only a 13mm nut holding the tensioner on the stud, just whip it off and have a good look at it. it should locate with a push firmly onto the side of the block.