1990 Peugeot 205 GTi 16v refurbishment
  • Register
  • Help
Page 1 of 4 1234 Last
Results 1 to 25 of 87
Like Tree34Likes

Thread: 1990 Peugeot 205 GTi 16v refurbishment

  1. #1
    Fellow Frogger! renn_205's Avatar
    Join Date
    Apr 2003
    Location
    Bondi Beach, Sydney
    Posts
    221

    Default 1990 Peugeot 205 GTi 16v refurbishment

    My little Pug 205 s16 "Peggy" is in need of some tender loving care, and since I don't have the time or skills, best to hand it to a professional. "Bluey" as he is known on Aussie, has been commissioned to refurbish her, with the following objectives:

    Advertisement


    1- TIDY HER UP;
    - clean up the previous s16 conversion (electrics, plumbing)
    - make it reasonable to service (and keep your limbs and tools)
    - Update the dash; no more broken plastic (for a while)

    2- CLAM HER DOWN;
    - road friendly ride; I've only been to the track once!
    - quiet down the exhaust. It is a bit unbearable, and antisocial!
    - keep the Air Conditioning

    3- IMPROVE HER
    - tune it
    - brake and suspension upgrades
    - power steering update


    Peggy up close and personal

    Never hard to find a parking spot!

    The engine bay before shot; with the (306) s16 donk taking up a lot of room!

    I have owned Peggy since 2001, and I had the original s16 conversion carried out in 2007 (thread lost in the AF crash?). However it wasn't the tidiest job, also some of the work on the suspension and exhaust was just too much and detracted from the driving experience. So the intent is to bring her back to a enjoyable drive for the road.

    Renn
    1990 Peugeot 205 s16
    Last edited by renn_205; 2nd February 2016 at 10:10 PM.
    SilverGTi_6, SamR and frog like this.
    Renn
    Peugeot 205 s16
    Megane RS 225 Cup

  2. #2
    1000+ Posts CEyssens's Avatar
    Join Date
    Jan 2016
    Location
    Berwick VIC AUS
    Posts
    1,045

    Default

    Nice car, so what's the plan for changes to make it more enjoyable on the street?

  3. #3
    Fellow Frogger! renn_205's Avatar
    Join Date
    Apr 2003
    Location
    Bondi Beach, Sydney
    Posts
    221

    Default

    The engine and gearbox have been removed, which (expectedly) revealed a lot of items that need repair or replacement.

    Some of the bigger items (already known):
    - worn clutch
    - leaking radiator & other coolant system components need replacement
    - power steering pump stuffed
    - exhaust is mismatched to the s16 manifold (despite being custom)













    Renn
    1990 Peugeot 205 s16
    Renn
    Peugeot 205 s16
    Megane RS 225 Cup

  4. #4
    Fellow Frogger! renn_205's Avatar
    Join Date
    Apr 2003
    Location
    Bondi Beach, Sydney
    Posts
    221

    Default

    Quote Originally Posted by CEyssens View Post
    Nice car, so what's the plan for changes to make it more enjoyable on the street?
    Mostly undo my previous mistakes with the original s16 conversion! The suspension and exhaust modifications. Then replace the interior plastics.

    The first thing I (un)did was to take out the Koni yellow (adjustable) struts and setting back to the standard ride height (it was lowered 40mm).

    Best decision I have made (meaning my previous was terrible
    )! The car is far more comfortable, compliant, predictable, responsive, and as sure footed as ever.

    The second will be to quiet down the exhaust, it is just a bit unbearable (and embarrassing) at particular engine speeds.

    In short, I have learned that it is true what other (wiser) AF members say, it is hard to improve on the original setup for the road... And an LSD is an absolute must on a 205 GTi!


    Renn
    1990 Peugeot 205 s16
    lozenge and CEyssens like this.
    Renn
    Peugeot 205 s16
    Megane RS 225 Cup

  5. #5
    1000+ Posts Isis's Avatar
    Join Date
    Nov 2010
    Location
    Melbourne
    Posts
    1,100

    Default

    don't lose the faith, this is all totally worth doing (again).
    renn_205 likes this.
    S3 205 GTI x 4 and getting lower
    1998 S1 Lotus Elise
    2013 Fiesta ST
    2014 Audi SQ5

  6. #6
    Fellow Frogger! renn_205's Avatar
    Join Date
    Apr 2003
    Location
    Bondi Beach, Sydney
    Posts
    221

    Default 1990 Peugeot 205 GTi 16v refurbishment

    Bit of a delay with this update; Huw is waiting for parts, however a couple of weeks ago he manage a bit of work on the engine.

    Base engine seems good
    - The valves are sealing well.
    - Good compression.
    - Camshafts and lifters are wearing well.
    - Camshafts linished and refaced the lifters.
    - Cam and coil covers stripped, bead blasted and repainted with fresh crinkle paint to make them look new. I just need to rub back the paint on the ribs to expose the aluminium, like factory.
    - Allen key bolt head welded to Sump plug (it was damaged)
    - Blown exhaust manifold gasket
    - The rear bearings and beam are excellent.
    -BakerBM Mi16 hose kit arrived


    Nudie Engine


    Innards


    Cam Cover ready for Stripping!


    Stripped bare!


    Like new!

    With the primary intent of the refurb to be a good road car, it is desirable to keep the AC.

    Huw, has pointed out the difficulties of achieving this, especially since part of the "Tidy Her Up" which involves keeping good clearance at the front.

    At this point Huw's strategy is to keep the standard (306s16) ECU, modify the shortened 1.9L manifold (I supplied to replace the s16 manifold), use the standard radiator, and rig up an oil filter. As Huw explained to me, the whole setup will be simpler (even with manifold, oil filter and sensor modifications), more reliable, and cost effective.

    The other option would be the more expensive Gti6 inlet, custom radiator/oil cooler setup as per Richard's 205.
    Richard's 205 GTi6 project

    Drivetrain wise, it will most likely back to standard front springs and ride height. As all the struts need replacing, I am considering Bilstien B6s, as well as a cutdown GTi6 rear sway bar. The disc brakes are also not far from replacement, so slotted rotors for the front (it runs 266 currently) with endurance pads will probably on the cards.

    Once some parts turn up, more can happen!

    Renn
    1990 Peugeot 205 s16
    Last edited by renn_205; 2nd February 2016 at 09:25 PM.
    Renn
    Peugeot 205 s16
    Megane RS 225 Cup

  7. #7
    Fellow Frogger! renn_205's Avatar
    Join Date
    Apr 2003
    Location
    Bondi Beach, Sydney
    Posts
    221

    Default 1990 Peugeot 205 GTi 16v refurbishment

    Huw has made a little more progress!

    Engine is prepped less 2nd hand parts trying to be sourced. The only other time the engine has been this clean, is when it rolled out of the factory!




    New small pulley PAS pump is on.


    Gearbox cleaned and has all new seals fitted


    Diff has 3.94 ratio (from original 75Kw 8v), and the Quaife looks fine (from original conversion)


    Just need more spare parts; check out the link below and maybe we can help each other out!
    Wanted - Various Pug/Cit parts



    Renn
    1990 Peugeot 205 s16
    Renn
    Peugeot 205 s16
    Megane RS 225 Cup

  8. #8
    1000+ Posts PeterT's Avatar
    Join Date
    Jul 2000
    Location
    Castle Hill, Sydney
    Posts
    7,416

    Default

    I spy a #2 pulley on the inlet. I'd be swapping it for a #3 while you have the chance. Or does it have an offset key?

    '92 205 Mi16
    '90 Mi16x4

  9. #9
    Fellow Frogger! renn_205's Avatar
    Join Date
    Apr 2003
    Location
    Bondi Beach, Sydney
    Posts
    221

    Default

    Quote Originally Posted by PeterT View Post
    I spy a #2 pulley on the inlet. I'd be swapping it for a #3 while you have the chance. Or does it have an offset key?
    You just asked something completely out of my expertise, Peter (ie, vaguely engine related)!

    Huw?!

    I did get a stage 1 regrind from you at the time of the original s16 conversion, I think it came with the offset? But its stretching my memory. Am I close to what you mean?


    Renn
    1990 Peugeot 205 s16
    Renn
    Peugeot 205 s16
    Megane RS 225 Cup

  10. #10
    Fellow Frogger! Bluey's Avatar
    Join Date
    Oct 2003
    Location
    Sydney
    Posts
    614

    Default

    Quote Originally Posted by PeterT View Post
    I spy a #2 pulley on the inlet. I'd be swapping it for a #3 while you have the chance. Or does it have an offset key?
    In/Out: 426B/Standard & 2/2 cam gears. No offset key.

  11. #11
    Fellow Frogger! renn_205's Avatar
    Join Date
    Apr 2003
    Location
    Bondi Beach, Sydney
    Posts
    221

    Default

    Quote Originally Posted by Bluey View Post
    In/Out: 426B/Standard & 2/2 cam gears. No offset key.
    Someone is going to have explain this one to me!


    Renn
    205s16
    Renn
    Peugeot 205 s16
    Megane RS 225 Cup

  12. #12
    Fellow Frogger! renn_205's Avatar
    Join Date
    Apr 2003
    Location
    Bondi Beach, Sydney
    Posts
    221

    Default

    And a wittle more...

    Finally I have a 205 oil pressure sensor with the thread adapter for it to fit the iron block, so now it reports properly.


    Excellent condition coolant distribution block and good knock sensor fitted.


    repaired thermostat housing as the necks were heavily corroded.







    Renn
    205s16
    Renn
    Peugeot 205 s16
    Megane RS 225 Cup

  13. #13
    1000+ Posts jo proffi's Avatar
    Join Date
    May 2003
    Location
    sydney
    Posts
    8,376

    Default

    Quote Originally Posted by renn_205 View Post



    Renn
    205s16
    Very nice welding job!

    Jo

  14. #14
    1000+ Posts PeterT's Avatar
    Join Date
    Jul 2000
    Location
    Castle Hill, Sydney
    Posts
    7,416

    Default

    Quote Originally Posted by Bluey View Post
    In/Out: 426B/Standard & 2/2 cam gears. No offset key.
    The inlet is probably at 113 LCL at present. Ideally you need to move it around to 109-110, which can be achieved with #3 pulley.

    Do you still need the small outlet on the thermostat housing?

    '92 205 Mi16
    '90 Mi16x4

  15. #15
    Fellow Frogger! Bluey's Avatar
    Join Date
    Oct 2003
    Location
    Sydney
    Posts
    614

    Default

    A few updates.

    You can see in the previous pics that someone fitted brass Welch plugs to the head. It's no wonder the thermostat housing and the distribution block were so heavily corroded. I replaced them with steel plugs expecting the water galleries to be eaten away but they were perfect. The housings must be an alloy more susceptible.



    Finally got the last bits for the engine thanks to some legendary Froggers, (you know who you are).



    Fresh bearings for the alternator too.



    But before the drivetrain could go in the front apron needed some attention courtesy of someone with a can opener and a penchant for plumbers fittings.






  16. #16
    Fellow Frogger! Bluey's Avatar
    Join Date
    Oct 2003
    Location
    Sydney
    Posts
    614

    Default

    From this....





    ...to this.




    Now with the repairs made not only is the insurance policy now valid but the engine can go in.

  17. #17
    Fellow Frogger! Bluey's Avatar
    Join Date
    Oct 2003
    Location
    Sydney
    Posts
    614

    Default

    Pushing the car around the workshop with no driveshafts fitted, one of the front hubs decided to spit half the bearing on the ground. I unbolted the brake caliper and the rotor fell onto the ground, hub still attached. What else fell onto the ground were several specially made spacers crafted from a Jim Beam can. Who ever did the 266mm brake conversion for Renn had ground back the mounting face of the caliper with an angle grinder to match the offset of the rotor, ground too much off, then packed out the gap with the makeshift shims. The mounting face wasn't even flat to the point that it's lucky the bolts didn't come loose.



    It was then we discovered the car still had Series 1 hubs fitted hence the ridiculous grinding. Time to find some Si hubs and freshen them up with new bearings.



    Also started hunting for some new anti-roll bar bushes. Oil had detroyed them.


  18. #18
    Fellow Frogger! Bluey's Avatar
    Join Date
    Oct 2003
    Location
    Sydney
    Posts
    614

    Default

    Back to the top of the bay and replacing the fuel filter lead to the discovery of a kinked outlet banjo. Ouch!



    Injectors look nasty and have been sent out for flow testing and service.


    Don't know what has been in the rail. Ethanol?


    Renn is adamant the car must have Air-con. Using the now standard radiator mounting I need to navigate this belt.


    The original XU10 inlet manifold appears to be the largest of all XU 16Vs. There is no hope of it fitting with a standard radiator mounting. Along comes a 30mm shortened XU9 Mi16 manifold. It won't fit because the end touches the power steering pump. "Chop it off", I thought. "It will fit", I thought. Like hell. I'm not sure if its because the curve has changed when it was welded together or because all 1.9L manifolds are that shape but the two bolts for the power steering pump would have to sit inside the runner space for it to fit.



    Back to the drawing board on that one.

  19. #19
    1000+ Posts schlitzaugen's Avatar
    Join Date
    Nov 2010
    Location
    loneliness capital of the world
    Posts
    8,777

    Default

    Time for a custom made manifold and restore the original length too.
    ACHTUNG ALLES LOOKENPEEPERS

    Das computermachine is nicht fur gefingerpoken und mittengrabben. Ist easy schnappen der springenwerk, blowenfusen und poppencorken mit spitssparken. Ist nicht fur gewerken bei das dummkopfen. Das rubbernecken sightseeren keepen hands in das pockets-relaxen und watch das blinkenlights.

  20. #20
    Fellow Frogger! Bluey's Avatar
    Join Date
    Oct 2003
    Location
    Sydney
    Posts
    614

    Default

    And finally, Kudos has to go to Renn for undertaking this restoration. The car has been a veritable Pandora's box and 99% of people would have stripped it for parts and sent the shell to the crusher had they known the condition of the mechanicals. I am hoping that by the end of this project that 'Peggy' can firmly plant itself in the top 10 205s in the country.
    renn_205 likes this.

  21. #21
    Fellow Frogger! Bluey's Avatar
    Join Date
    Oct 2003
    Location
    Sydney
    Posts
    614

    Default

    Quote Originally Posted by schlitzaugen View Post
    Time for a custom made manifold and restore the original length too.
    Original length is definitely going to be an aim. Probably going to use the single XU10 Mi16 throttle body.

    Custom manifold and a standard ECU. Sound wacky?

    I have been thinking of a cut and shut of the alloy section of the XU10 manifold and using the vac-pod operated throttle plates to convert it to individual throttle bodies but I don't think the ECU will be able to supply enough initial fuel when the throttle is cracked open, particularly in the lower half of the rev range, and the engine will momentarily cut out/hesitate/stumble.

  22. #22
    Fellow Frogger! Bluey's Avatar
    Join Date
    Oct 2003
    Location
    Sydney
    Posts
    614

    Default

    Managed to remove all the rust from the fuel rail by bead blasting. Fitted up the freshly serviced injectors only to discover that the XU10 rail mounting holes are offset on the XU9 manifold flange.



    A piece of heater hose showing how much length I need to find for these runners.




  23. #23
    1000+ Posts
    Join Date
    Jul 2001
    Location
    Perth, Western Australia
    Posts
    6,248

    Default

    Top work Bluey. Great thread.
    renn_205 likes this.


    2003 PEUGEOT 206 GTi

  24. #24
    Fellow Frogger! chez00's Avatar
    Join Date
    Nov 2010
    Location
    Adelaide
    Posts
    567

    Default

    Looking good. I fit a gti6 manifold to my 2.0l Mi16 engine, and it fit without shortening, has the notch for the pas pump (I don't run pas or AC) and the xu10 fuel rail bolts straight on. Better flow, better throttle body.

    Lots of plumbing required though to relocate the oil fill can etc.

    May be an option though?
    1988 205 GTi XU10J4
    2001 406 Monaco 5sp V6

  25. #25
    Fellow Frogger! renn_205's Avatar
    Join Date
    Apr 2003
    Location
    Bondi Beach, Sydney
    Posts
    221

    Default

    Quote Originally Posted by chez00 View Post
    Looking good. I fit a gti6 manifold to my 2.0l Mi16 engine, and it fit without shortening, has the notch for the pas pump (I don't run pas or AC) and the xu10 fuel rail bolts straight on. Better flow, better throttle body.

    Lots of plumbing required though to relocate the oil fill can etc.

    May be an option though?
    Absolutely... got a spare, cause we Couldn't find one!


    Renn
    205s16
    Renn
    Peugeot 205 s16
    Megane RS 225 Cup

Page 1 of 4 1234 Last

Thread Information

Users Browsing this Thread

There are currently 1 users browsing this thread. (0 members and 1 guests)

Posting Permissions

  • You may not post new threads
  • You may not post replies
  • You may not post attachments
  • You may not edit your posts
  •