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Author Subject: Project PUG
rikky 🦔

Location: cheshire

Registered: 28 Feb 2004

Posts: 26,796

Status: Offline
Post #226
i forget to be honest, i know the red plug [out of the red and brown main ones at the dash] has one red wire on it running right to the fuel pump area. it maychange to another colour somewhere, i don't honestly remember now that it's all back together

i don't even have that whole door loom atall or any of the loom that runs to the wiper mechanism or anything at the back window

________________________________________

306 rallye reproduction decals (full sets/individual decals) | 306 b-pillar textured vinyl weatherstrips
306 slam panel esso stickers | 306 yellow / orange / pension fund red side door badges
gti6 inlet manifold badges | 306 rear boot badges (p2/p3)
winner of Extraction of toys from prams with outstanding vigour award 2009 [source: gti6 owners club]
Posted 18th Dec 2008 at 15:12
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rikky 🦔

Location: cheshire

Registered: 28 Feb 2004

Posts: 26,796

Status: Offline
Post #227
chris with a pug wrote:
On mine its blue, there is a red one on there two, think its useless now, but not sure


you are right, the red plug from the dash [on mine] has one wire in now all the way to the fuel pump, and the wire is a baby blue colour. all others from that plug have been stripped

________________________________________

306 rallye reproduction decals (full sets/individual decals) | 306 b-pillar textured vinyl weatherstrips
306 slam panel esso stickers | 306 yellow / orange / pension fund red side door badges
gti6 inlet manifold badges | 306 rear boot badges (p2/p3)
winner of Extraction of toys from prams with outstanding vigour award 2009 [source: gti6 owners club]
Posted 19th Dec 2008 at 02:16
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chris with a pug

Seasoned Pro

Location: Southampton

Registered: 16 Feb 2003

Posts: 5,366

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Post #228
Hmmmm I wonder what the other one does
Posted 19th Dec 2008 at 02:19
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rikky 🦔

Location: cheshire

Registered: 28 Feb 2004

Posts: 26,796

Status: Offline
Post #229
just follow it back Unsure must go somewhere, grab the haynes when you backtrack it to the plug or whatever and find the wire number

________________________________________

306 rallye reproduction decals (full sets/individual decals) | 306 b-pillar textured vinyl weatherstrips
306 slam panel esso stickers | 306 yellow / orange / pension fund red side door badges
gti6 inlet manifold badges | 306 rear boot badges (p2/p3)
winner of Extraction of toys from prams with outstanding vigour award 2009 [source: gti6 owners club]
Posted 19th Dec 2008 at 04:04
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chris with a pug

Seasoned Pro

Location: Southampton

Registered: 16 Feb 2003

Posts: 5,366

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Post #230
Right been doing a few bits and peices over the holidays, removed more spot welded mounts in side. think I pretty much have them all out now.
I have almost finished getting the sound deadning off the floor.
Undersealed the rear arches.
before:


after:


I found out what the read wire is for, its for the heated rear window.
Can anyone tell me what this is as I cut the wire off for it in the loom so I am assuming its redundant, but just want to check

Also I have now ordered my conrods, so will be able to get the engine pretty much back together as I have everything else.
One thing I am woried about is I have one of the old batch of lightened fly wheels and I found out the reason why they changed the design at the recent rolling road day, so am going to get the teeth heat treated.
Think that it everythnig
Posted 30th Dec 2008 at 18:11
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simgti6

Senior User

Location: Walsall

Registered: 10 May 2003

Posts: 730

Status: Offline
Post #231
The two wires above are for the tilt switch, to make the boot light come on when you open the boot
Posted 30th Dec 2008 at 18:37
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chris with a pug

Seasoned Pro

Location: Southampton

Registered: 16 Feb 2003

Posts: 5,366

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Post #232
oh cool thats why its cut then as I removed the boot light, I was worried for a bit
Posted 30th Dec 2008 at 18:39
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-er-

Junior User

Location: Istanbul / Bodrum

Registered: 20 Sep 2007

Posts: 73

Status: Offline
Post #233
Good job (Y)

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Posted 5th Feb 2009 at 23:48
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chris with a pug

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Location: Southampton

Registered: 16 Feb 2003

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Post #234
So not really updated this for a while.
I have just been romoving more stuff from the interior. Nearly there now.
The block is off to be machined this week along with the head, which is being skimmed and new guides fitted, hope to have this back by next weekend and if I am not working fit the head back together or atleast get all the valves lapped in.
Posted 1st Feb 2009 at 17:51
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chris with a pug

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Location: Southampton

Registered: 16 Feb 2003

Posts: 5,366

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Post #235
Right a quick update on this as not posted for ages.
The head is at the engineers, all the guilds refitted and now he just has to check they all seal and if not he will recut the seats.
Went to pug and ordered the engine gasket kit and it doesnt bloody come with a head gasket, bloody stupid if you as me so will need to get in and order that when i get the head bolts and cam belt stuff next week.
The block will be going when I pick the head up then I can get the engine finally back together, but an not gonig to rush it, want to measure everything and double check it all.
Here is the gasket kit,




also some new core plugs


and the new design oil sproket at mine had the older type one



Also had the holes welded up on a set of doors, i know they are not to everyones taste, but there my doors and i like it.
Sorry i dont have any of them in primer yet



and also I painted my fuel rail



and also picked this up for a bargian 60 quid



will start to update this again as will be trying to finish the car.
Posted 19th May 2009 at 01:14
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adam001

Regular

Location: Camberley & Loughborough

Registered: 12 Mar 2009

Posts: 109

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Post #236
Hmm not sure that exhaust manifold will do you any favours it's not even equal length
Posted 27th May 2009 at 03:57
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chris with a pug

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Location: Southampton

Registered: 16 Feb 2003

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Post #237
Was a bit of an impulse buy, you think it will be crap then?
Posted 27th May 2009 at 04:28
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welshpug!

Capt Pedantic

Location: Bigend, Wales.

Registered: 27 Mar 2007

Posts: 25,838

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Post #238
yeap, stick to the standard one till you're well over the 200 bhp mark n/a.

________________________________________

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

Bring on the Trumpets.

Posted 27th May 2009 at 14:52
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daveyboy

aka Jim Davey

Location: Southampton

Registered: 01 Oct 2007

Posts: 8,648

Status: Offline
Post #239
welshpug! wrote:
yeap, stick to the standard one till you're well over the 200 bhp mark n/a.


Have you read the rest of this thread? He's building a high boost S/C engine Roll eyes

________________________________________

R H Davey Welding Supplies. I sell new and used welding equipment in the Hampshire area. I take on welding jobs in the evenings, ally casting repairs are one of my specialities but I can weld pretty much anything. PM me with your requirements.

Some of my services: (See my for sale threads)
Engine mount/chassis repair
Solid Beam Mounts BACK IN PRODUCTION
Harness bars
Posted 27th May 2009 at 15:05
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chris with a pug

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Location: Southampton

Registered: 16 Feb 2003

Posts: 5,366

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Post #240
Its going to be a high boost engine! still no good?
Posted 27th May 2009 at 15:13
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daveyboy

aka Jim Davey

Location: Southampton

Registered: 01 Oct 2007

Posts: 8,648

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Post #241
adam001 wrote:
Hmm not sure that exhaust manifold will do you any favours it's not even equal length


It is equal length, if you look closer you will see that the longer of the two runners meet the two outlets in the centre of the flange with the shorter run on them. It will be just fine Chris once it's been tidied up a little.Smile

________________________________________

R H Davey Welding Supplies. I sell new and used welding equipment in the Hampshire area. I take on welding jobs in the evenings, ally casting repairs are one of my specialities but I can weld pretty much anything. PM me with your requirements.

Some of my services: (See my for sale threads)
Engine mount/chassis repair
Solid Beam Mounts BACK IN PRODUCTION
Harness bars
Posted 27th May 2009 at 15:22
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chris with a pug

Seasoned Pro

Location: Southampton

Registered: 16 Feb 2003

Posts: 5,366

Status: Offline
Post #242
I will grab it out the van when i take it to fords and go to town on it
Posted 27th May 2009 at 15:30
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welshpug!

Capt Pedantic

Location: Bigend, Wales.

Registered: 27 Mar 2007

Posts: 25,838

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Post #243
the engine gasket kit doesn't come with a head gasket as you need to fit a thicker gasket if you skim the head Wink

________________________________________

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

Bring on the Trumpets.

Posted 27th May 2009 at 16:50
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chris with a pug

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Location: Southampton

Registered: 16 Feb 2003

Posts: 5,366

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Post #244
since when? never heard of that thought all the gaskets where the same thickness
Posted 27th May 2009 at 16:57
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chris with a pug

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Location: Southampton

Registered: 16 Feb 2003

Posts: 5,366

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Post #245
So got up early this morinig and got cracking.

First thing was to cut all the inside of the doors out and the side impact bar, am having impact bars in the cage so dont need it and the phase 2s never came with them so i think ill be safe.





then i set about rubbing all the primer down



with that pretty much sorted I then set about cleaning all the joins in the car and removing the seam sealer, takes for ever and is really boring but am getting there with it now, almost ready to be welded infact.


Tomorrow i hope to have my head back and can get that togehter.
And my block is going to the engineers tomorrow as well
Posted 28th May 2009 at 20:47
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chris with a pug

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Location: Southampton

Registered: 16 Feb 2003

Posts: 5,366

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Post #246
So I stopped off at the engineers and got my head back, got the valves fitted and the lifters,very tight to get in. but rubbed a bit of oil on them and they went in pretty easily.

Then fitted the cams

Got some locktite gasket from halfords, 10 quid cheaper than pug, then got about applying it to the cam carriers.

Got them all bolted down, my torque wrench dont go as low as 10 so i guessed it, didnt go too tight at all.
then put in my new seals I got with my kit

the head pretty much together now, just needs the plastic bit putting on, which i cant find. is in thew garage somewhere.

here is the gasket stuff

I used a laser valve tool from halfords and was pretty impressed with it, for 24 quid
.

Would also like to thank Rich, I have the old type lightened fly wheel, he rang me today saying he would swop it for a newer stronger one Smile so thanks mate.
Wont do much more this month as spent out and need to get my block to the engineers (different one that did the head) and thats gonna cost about 200 notes.
Posted 10th Jun 2009 at 00:33
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daveyboy

aka Jim Davey

Location: Southampton

Registered: 01 Oct 2007

Posts: 8,648

Status: Offline
Post #247
Nice work Chris, looking really good mate. You getting Osslebury to do the block?

________________________________________

R H Davey Welding Supplies. I sell new and used welding equipment in the Hampshire area. I take on welding jobs in the evenings, ally casting repairs are one of my specialities but I can weld pretty much anything. PM me with your requirements.

Some of my services: (See my for sale threads)
Engine mount/chassis repair
Solid Beam Mounts BACK IN PRODUCTION
Harness bars
Posted 10th Jun 2009 at 05:54
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rikky 🦔

Location: cheshire

Registered: 28 Feb 2004

Posts: 26,796

Status: Offline
Post #248
out of interest what did you clean the inside of the shell/footwells up with? wire wheel?

________________________________________

306 rallye reproduction decals (full sets/individual decals) | 306 b-pillar textured vinyl weatherstrips
306 slam panel esso stickers | 306 yellow / orange / pension fund red side door badges
gti6 inlet manifold badges | 306 rear boot badges (p2/p3)
winner of Extraction of toys from prams with outstanding vigour award 2009 [source: gti6 owners club]
Posted 10th Jun 2009 at 05:56
Profile
daveyboy

aka Jim Davey

Location: Southampton

Registered: 01 Oct 2007

Posts: 8,648

Status: Offline
Post #249
He did it with a twist-knot wire brush that goes on the 4.5" angle grinder I sold him Big grin

Very effective but pretty vicious if you catch it on an edge of something, eye protection is a necessity! Dry

________________________________________

R H Davey Welding Supplies. I sell new and used welding equipment in the Hampshire area. I take on welding jobs in the evenings, ally casting repairs are one of my specialities but I can weld pretty much anything. PM me with your requirements.

Some of my services: (See my for sale threads)
Engine mount/chassis repair
Solid Beam Mounts BACK IN PRODUCTION
Harness bars
Posted 10th Jun 2009 at 06:14
Profile
rikky 🦔

Location: cheshire

Registered: 28 Feb 2004

Posts: 26,796

Status: Offline
Post #250
yeah, been using mine on various things, was going to try it on a spare wheel but didn't know what the outcome would be and if it would seriously f*ck my alloy - so they can go to the refurbishers instead LOL

________________________________________

306 rallye reproduction decals (full sets/individual decals) | 306 b-pillar textured vinyl weatherstrips
306 slam panel esso stickers | 306 yellow / orange / pension fund red side door badges
gti6 inlet manifold badges | 306 rear boot badges (p2/p3)
winner of Extraction of toys from prams with outstanding vigour award 2009 [source: gti6 owners club]
Posted 10th Jun 2009 at 06:21
Profile
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