Little Silver 205GTI

Update on work from Sunday

Box back in, now to reassemble, fully eliminate the hydraulic clutch and put back all the original spec clutch parts, pedal, cable and linkages... little silver is feeling happier already

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Happy days [emoji106]
 
Wow - that 18YO pressure plate has been waiting a while for it's turn ! Aren't push type clutches wonderful ! The BE3/6 in my GTi6 was a bugger......

Cheers

Justin
 
N5GTi6 said:
Wow - that 18YO pressure plate has been waiting a while for it's turn ! Aren't push type clutches wonderful ! The BE3/6 in my GTi6 was a bugger......

Cheers

Justin
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Hey Justin, yeah the pressure plate was finished, clutch was fine but check out the thrust bearing, totally stuffed, seized and the inner collar was in a right mess. I don’t think it had done much work by the look of the clutch plate. What issues did you have wit the gti6?
 
CEyssens said:
Hey Justin, yeah the pressure plate was finished, clutch was fine but check out the thrust bearing, totally stuffed, seized and the inner collar was in a right mess. I don’t think it had done much work by the look of the clutch plate. What issues did you have wit the gti6?
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The 'pull' type clutch on the be3/6 is just tricky to engage when you're reinstalling the gearbox because you have to hook the clutch fork in behind the release bearing as you slide the gearbox back onto the engine. Maybe just tricky doing it by myself - might have been easier with another pair of hands.

Cheers

Justin
 
Lots of small details getting done

Gearbox back on its (not so rusty anymore) mount
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AFM inlet replaced
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Bent and damaged AFM bracket replaced
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Dodgy clutch pedal that was modified for the hydraulic clutch now replaced
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BE1 missing clutch link arm sorted out inc new bushes
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Lots of old hoses replaced
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Missing ignition lead tray sorted out
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Damn she looks so similar to mine. Keep going it might motivate me.
 
Oh and I got this in the mail recently and it even turned up in one piece!
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Now just to find the other S1 dash parts in this condition (I know crazy right?!)
 
Fuel Pressure Switch?? Has anyone ever seen a fuel pressure switch on their 205 GTI?

I'm figuring the answer is no, but thought to ask in case I'm off the money on this.
I've removed the aftermarket bodged fuel filter and it's got a two wire switch on the bottom, I'd say its a pressure switch, but no idea yet what it connects to.
 
Some Euro models had that safety feature as well. You can see it in the wiring diagrams. It was a resettable switch on the inner wing, don't remember which side. I think it killed the pump in the event of a collision.
 
Snuck in an hour on the tools today

Dusted off the driveshafts and popped them back in. Finished off the clutch cable and linkages work. Deleted the oil cooler and fitted the new filter in the remote location. And prepped inlet manifold ready to go back in.


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schlitzaugen said:
Your engine needs a wash.
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It certainly does... leaky rear main among other leaks and lots of years of not being cleaned.... everything that's touched is getting a freshen up and it will get a big clean once it's running again.
 
CEyssens said:
It will get a big clean once it's running again.
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It's going to be good! It's hard to clean things up once its all assembled again. I'd be using some soft wire brushes on drill and Dremel to clean up the cam cover, inlet manifold and visible parts of the head now before its all reassembled.

And don't let any of the cognoscenti see that you fitted a Ryco filter instead of a Purflux...
 
It's going to be a pig to change the main rear seal after you put the 'box back in. Why not do it now?

I would suggest you leave the rest dirty until you have it all assembled and then make sure it starts and runs very well.

Then use a high pressure washer to take all that grime off then check spark plug tubes (blow water out with compressed air) and dizzy (wipe it dry inside and out or use tons of alcohol sprayed on it), then start the engine and take the car for a drive to dry everything thoroughly in the engine bay.

Try to avoid washing the connectors, even though Bosch type should be water tight. A light spray won't harm them.
 
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