SG9 Forester STi
Welcome to my 205 GTi project thread...which I blame entirely on Daniel for posting pictures of his mint one! :evil:
The car is a ph1 205 gti 1.6 1986 model. This is our second project car atm and is taking priority over the Sierra which is more of a long term project.
The car was purchased in Jan 2011 with the intention, here comes the joke, to be used as a daily runabout, 'normal' cars are boring lol. It's an iconic french hot hatch and I've always wanted one!
Car history:
It's previous owner had owned the car for 5 years and in that time, it's fair to say, he didnt show it any mercy. The car was stripped and bucket seated up and spent it's entire career with him as a professional rallycross car (a very successful one at that i'm told) until the original 1.6 unit blew up on him. In his workshop it sat amongst other competition cars for a couple of years, an empty shell, until he decided to get it up and running again as a trackday car. For this he found an 80k later 1990 spec more powerful 1.6 engine to replace the dead lump. However after fitting he lost time and space for it as the bodywork was suffering so it went up for sale.
The car was bought for the low sum of £500 with four bald tyres and only the interior he could find, massively incomplete. But alas the drivers seat was bolted in and seatbelt fitted so I was able to drive it home at least.
A nice surprise hiding behind this :dead::
This will be a 'no messing' speed project with all available funds being thrown at it. It's taking priority over the Sierra, the green thing and the 197 until it's roadworthy and of presentable condition.
Engine Issues:
The car was run around in for a few days and it's evident there's a catastrophic coolant leak - dumping an entire systems worth in around 100 easy going miles.
The car was inspected for the leak and it was soon obvious the leak was coming from the head gasket on the right side of the block, bad times :dapprove:.
This was confirmed by this mess found in the oil filler neck:
So the head gasket has blown! Before any work begun it was time to give the engine a full inspection to see what we were up against:
The jet washer was cracked out and the engine cleaned as best possible including a massively oil covered diff casing...
Now shiny and clean:
The oil leak was thanks to a leaking camshaft seal hidden behind the distributor, all the more reason to rip it out:
Then it was time for some strippage
...
Intake manifold removed
To gain access to the lower section of the cambelt and the tensioner the wheel had to be removed and arch linings stripped down. Then two coolant hoses removed plus alot of plastic covering:
The cambelt was finally removed:
Back on top and an hour or so later:
New head bolts, gasket and water pump were ordered from Peugeot..expensive! Whilst there it was decided to do a basic cylinder head rebuild consisting of stem seals and adjusting the tappets via the shim system.
Next the head:
The head is to be stripped down and rebuilt with new studs, seals and gaskets along with a skim as a precaution and to raise compression slighlty. No warping is evident.
It will then be reshimmed by a professional as Peugeot have seized production on the shims so they are as rare as gold dust and just as expensive.
We've also been toying with the idea of a fast road camshaft but trying to keep the majority standard and just recon'd. The head is of the later 1990 model so already incorporates the larger valves and better flowing ports, result!
Head retrieved from storage lol:
Parts stripped off:
Thermostat housing removed but the gasket refused to budge, requiring some good old graft to clean up:
A lot of sandpaper and an hour later:
Still too untidy though:
Much better, halfords high temp paint FTW:
Great finish:
That's it so far...
Thanks for reading watch this space for more updates soon!!!
The car is a ph1 205 gti 1.6 1986 model. This is our second project car atm and is taking priority over the Sierra which is more of a long term project.
The car was purchased in Jan 2011 with the intention, here comes the joke, to be used as a daily runabout, 'normal' cars are boring lol. It's an iconic french hot hatch and I've always wanted one!
Car history:
It's previous owner had owned the car for 5 years and in that time, it's fair to say, he didnt show it any mercy. The car was stripped and bucket seated up and spent it's entire career with him as a professional rallycross car (a very successful one at that i'm told) until the original 1.6 unit blew up on him. In his workshop it sat amongst other competition cars for a couple of years, an empty shell, until he decided to get it up and running again as a trackday car. For this he found an 80k later 1990 spec more powerful 1.6 engine to replace the dead lump. However after fitting he lost time and space for it as the bodywork was suffering so it went up for sale.
The car was bought for the low sum of £500 with four bald tyres and only the interior he could find, massively incomplete. But alas the drivers seat was bolted in and seatbelt fitted so I was able to drive it home at least.
A nice surprise hiding behind this :dead::
This will be a 'no messing' speed project with all available funds being thrown at it. It's taking priority over the Sierra, the green thing and the 197 until it's roadworthy and of presentable condition.
Engine Issues:
The car was run around in for a few days and it's evident there's a catastrophic coolant leak - dumping an entire systems worth in around 100 easy going miles.
The car was inspected for the leak and it was soon obvious the leak was coming from the head gasket on the right side of the block, bad times :dapprove:.
This was confirmed by this mess found in the oil filler neck:
So the head gasket has blown! Before any work begun it was time to give the engine a full inspection to see what we were up against:
The jet washer was cracked out and the engine cleaned as best possible including a massively oil covered diff casing...
Now shiny and clean:
The oil leak was thanks to a leaking camshaft seal hidden behind the distributor, all the more reason to rip it out:
Then it was time for some strippage
...Intake manifold removed
To gain access to the lower section of the cambelt and the tensioner the wheel had to be removed and arch linings stripped down. Then two coolant hoses removed plus alot of plastic covering:
The cambelt was finally removed:
Back on top and an hour or so later:
New head bolts, gasket and water pump were ordered from Peugeot..expensive! Whilst there it was decided to do a basic cylinder head rebuild consisting of stem seals and adjusting the tappets via the shim system.
Next the head:
The head is to be stripped down and rebuilt with new studs, seals and gaskets along with a skim as a precaution and to raise compression slighlty. No warping is evident.
It will then be reshimmed by a professional as Peugeot have seized production on the shims so they are as rare as gold dust and just as expensive.
We've also been toying with the idea of a fast road camshaft but trying to keep the majority standard and just recon'd. The head is of the later 1990 model so already incorporates the larger valves and better flowing ports, result!
Head retrieved from storage lol:
Parts stripped off:
Thermostat housing removed but the gasket refused to budge, requiring some good old graft to clean up:
A lot of sandpaper and an hour later:
Still too untidy though:
Much better, halfords high temp paint FTW:
Great finish:
That's it so far...
Thanks for reading watch this space for more updates soon!!!
