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Author Subject: Project Rallye MUD
hanpug25

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Location: Wolverhampton

Registered: 08 Apr 2007

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Post #1
Some of you may have seen MUD in the for sale section over the last couple or weeks. Was advertised as needing work to the engine. I collected it last week and drove the 40 mile home with no issues.



The car really is immaculate, inside and out, even the drivers seat is prefect. Apart from a slight rattle from the engine, mechanically, its spot on.

Anyway, got the car home, and during the drive, had decided that the engine noise was 'pinking' (rather like the paint LOL ) so tried all of the obvious bits first - coil packs, injectors, sensors etc, but they were all spot on. Next was a compression test, with clear results. Cylinders 1 & 2 were a healthy and matching 220 psi. 3 & 4 were both showing 90psi, conclusion, blown headgasket between 3&4.

Started to sort it today, pics below:

Inlet off


Cambelt, pulley's & cam covers off


Pile of bits Blink


And after 2 hrs of knucle scraping, especially the exhaust bolts, Head off


And the offending break between 3&4


Heads going to the local head place Monday for a light skim to remove the marks left by the old gasket (only

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Passat B5.5 TDi estate (174bhp, 260 lbs/ft)
Posted 28th Nov 2009 at 21:45
paulste1978

Newbie

Location: Coventry

Registered: 12 Jan 2006

Posts: 44

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Post #2
Good work mate, Rallye is loads more fun, and more of a head turner you gotta keep it.

Why is it so pink in the pics? Is it a crap camera?

subscribed to thread now. Look forward to seeing it all finished.
Posted 28th Nov 2009 at 22:07
hanpug25

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Post #3
Camera phone! Still red in daylight, just the flash that pinks it a tad.

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Passat B5.5 TDi estate (174bhp, 260 lbs/ft)
Posted 28th Nov 2009 at 23:43
phillipm

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Location: Rotherham

Registered: 15 Oct 2006

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Post #4
I was expecting a filthy rally car with a title like that Sad

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Posted 29th Nov 2009 at 00:36
welshpug!

Capt Pedantic

Location: Bigend, Wales.

Registered: 27 Mar 2007

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Post #5
nice work, make sure you use a fatter head gasket to suit the head skim though, wouldn't want to turn it into a tapper!

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Posted 29th Nov 2009 at 01:32
hovis16

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Location: Reading/parts for sale

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Post #6
haha thats the reading mud rallye aint it? time to search

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Posted 29th Nov 2009 at 01:47
hovis16

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Post #7
no its not the reading one is starts T7 LOL

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Posted 29th Nov 2009 at 01:48
hanpug25

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Post #8
welshpug! wrote:
nice work, make sure you use a fatter head gasket to suit the head skim though, wouldn't want to turn it into a tapper!


Unsure Eh?

Does it need a thicker gasket regardless of how much/little is skimmed off? I thought Id gain a wee bit of compression Ninja

Confused now???

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Passat B5.5 TDi estate (174bhp, 260 lbs/ft)
Posted 29th Nov 2009 at 02:19
rapidcossie

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Location: falkirk

Registered: 30 Jun 2009

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Post #9
it will be cool on one skim mate.
Posted 29th Nov 2009 at 02:23
chris with a pug

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Location: Southampton

Registered: 16 Feb 2003

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Post #10
I would like to know about these thicker gaskets too as pug dont list them, do the exsist or is it just am myth,
Posted 29th Nov 2009 at 19:30
welshpug!

Capt Pedantic

Location: Bigend, Wales.

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Post #11
I see what you mean Chris, they don't for the RS engine, they do for the R however;


0209 T9, CR EP:1,40

its the same block so will work just fine.

what with the minimal clearance they have IMO its silly to skim a head and not compensate for it, though from what I've read Sandy said 0.25 is the max skim you can do anyway.

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Posted 29th Nov 2009 at 19:40
chris with a pug

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Post #12
is that headgasket the same as an RS one, i mean the multi layer ones
Posted 29th Nov 2009 at 19:56
welshpug!

Capt Pedantic

Location: Bigend, Wales.

Registered: 27 Mar 2007

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Post #13
no idea I'm afraid, I don't think it matters if its not, I saw a picture of a spesso "Racing gasket" a few days ago and that wasnt an MLS one.

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Posted 29th Nov 2009 at 20:00
hanpug25

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Post #14
Grabbed the head today on the way back from work, had to have 8 thou skimmed off due to the marks left from the old gasket. They had to take the inlet valves out to skim it, so gave it all a good clean (inlet cam looks brand new). Only charged

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Posted 30th Nov 2009 at 23:47
hanpug25

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Post #15
welshpug! wrote:
I see what you mean Chris, they don't for the RS engine, they do for the R however;


0209 T9, CR EP:1,40

its the same block so will work just fine.

what with the minimal clearance they have IMO its silly to skim a head and not compensate for it, though from what I've read Sandy said 0.25 is the max skim you can do anyway.


Compared the 'R' gaskets to the 'RS' one today. The former are not multi layer, the latter is.

Ad.

________________________________________

Passat B5.5 TDi estate (174bhp, 260 lbs/ft)
Posted 30th Nov 2009 at 23:50
welshpug!

Capt Pedantic

Location: Bigend, Wales.

Registered: 27 Mar 2007

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Post #16
8 thou is 0.20 of a mm, which is exactly how much thicker an XU10J4R repair gasket is than a standard one Smile

hope it never needs to come off again, as there's only 0.05 (2 thou) safe skim left Shock

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need a part number? get on here - http://public.servicebox.peugeot.com

Bring on the Trumpets.

Posted 30th Nov 2009 at 23:52
hanpug25

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Post #17
welshpug! wrote:
8 thou is 0.20 of a mm, which is exactly how much thicker an XU10J4R repair gasket is than a standard one Smile

hope it never needs to come off again, as there's only 0.05 (2 thou) safe skim left Shock


Thats what I thought when he told me, hope its not been off before, no way to tell.

He did have another RS head on the shelf, thats fully overhauled and had at least 50% of its valves replaced. Thats my backup plan LOL

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Passat B5.5 TDi estate (174bhp, 260 lbs/ft)
Posted 30th Nov 2009 at 23:59
hanpug25

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Post #18
head went back on and timing went well. measured the clearances before refitting and was uber close. Genuine gaskets seem worthh the dough.





Not much to photograph from this point. Exhausy manifold was the hardest and most Angry part of the refit. Must have checked and rechecked the timing 20 times Blink before i was happy.

Finally got it running and.....tap tap tap Crazy

But after 2 mins it quietened down and turned out to be the tappets filling due to them being removed for the skim....Phew

Took it for a subtle spin to get it up to temp, before letting it cool, and double checking all of the torque settings. Took it out again for a more enthusiastic drive, and it never missed a beat Big grin

306 Rallye with blown headgasket.....DONE

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Passat B5.5 TDi estate (174bhp, 260 lbs/ft)
Posted 10th Dec 2009 at 00:03
roland rat

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Post #19
Awesome work mate,will you be keeping her or selling it on?Whistle
Posted 6th Dec 2009 at 02:39
wilyoldave

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Post #20
Looking good mate, nice to see it back to full health - keep the rallye!

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Posted 6th Dec 2009 at 02:40
hanpug25

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Post #21
roland rat wrote:
Awesome work mate,will you be keeping her or selling it on?Whistle


Really dont know. Been driving the astor the past week or so and torn between the two Blink why, you fancy a red rallye Razz

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Posted 6th Dec 2009 at 02:53
hanpug25

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Post #22
CUJ wrote:
Shortest project thread ever? LOL

What are you going to do with her mate?


Dont know to be honest, got an Astor 6 too atm and need to sell one. Astor is my fav colour, but the rallye is by far the better car, even though its covered 35k more miles, but my wife hates the colour! Just stuck VTS axle & springs on the Astor too. Toss of a coin will have to decide.

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Passat B5.5 TDi estate (174bhp, 260 lbs/ft)
Posted 6th Dec 2009 at 02:57
roland rat

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Post #23
Both are lovely cars and i'd love either one but the house is raping me atm Sad
Posted 6th Dec 2009 at 03:11
fletch

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Post #24
hanpug25 wrote:

306 Rallye with blown headgasket.....DONE


Very Gordon Ramsay LOL
Posted 7th Dec 2009 at 00:27
hanpug25

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Post #25
roland rat wrote:
Both are lovely cars and i'd love either one but the house is raping me atm Sad


Get used to it, 4 years on and mines still at it LOL

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Passat B5.5 TDi estate (174bhp, 260 lbs/ft)
Posted 8th Dec 2009 at 01:24

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