Cully's spare Gti6 engine

[Sian]

You still didnt consider my offer there paul haha

[cully]

You still didnt consider my offer there paul haha

let me think on it

[Sian]

[cully]

VICTOR REINZ part numbers

Full Gasket Set With valve stem seals/crankshaft seal
01-35050-01
0197.W2
+0209.Z2

Cylinder Head Gasket Set with valve stem seals
02-35050-01

Bottom End/Crankcase Conversion Gasket Set
08-25918-04

Headgasket
61-35050-00
0209.Z2
86,5 mm
MLS

Head Bolts
14-32148-01
0204.72 (10x)

Valve stem seals
12-31306-01
70-31306-00 16x
0956.38

Inlet Gasket
71-33666-00
0348.C8

Exhust Gasket
71-34443-00
0349.F4

Build Paste
70-31414-10

CRANKSHAFT BEARING SEAL Front
81-25926-10 K ,
0326.12
42x62x8

CRANKSHAFT BEARING SEAL Rear
81-34456-00 K .
0127.28
90x110x7

Camshaft Oil Seal
81-34403-00 N 2x
0236.44
36x50x7

head bolt torque settings with tightening sequence

  head bolts.pdf (Size: 99.23 KB / Downloads: 8)

[cully]

ebay purchases have been slowly turning up
must go down to peugeot with my smaller list of gaskets i cant find cheaper

   

[Niall]

cully can you send me the link to the seals for the fly wheel end crank bracket? The long thin rubber ones. Having trouble finding the right ones!

[cully]

Peugeot part number 012740 BEARING SEAL 0.80 GBP

to be honest niall i search ebay with the part numbers and people are selling there bought spares as they have to buy bags of 10

oww maybe i shouldnt of said that as you will bump up my bids now

i have 6 here i only need 2 for the rear seal come collect the welder

[Niall]

Ill pinch two from you then when i come down if you don't mind? Also, my missus is useless and forgot to post the pullies. I found them in the boot of her car the other day lol. Want me to post them or keep hold till we come down for the welder?

[cully]

Parts pile is getting bigger
Inlet valve turned up today

FAI part number IV537141

   

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back to head gasket info......

1.4mm thick gasket non MLS peugeot number is 0209 T9 price is £53.27 i belive this is listed for the XU10J4 engine not the RS
this is used as a repair Gasket

this is the gasket i will be fitting to mine as the head is skimmed to the max -0.2mm
the gasket should take the measurement back to +0.0mm Standard giving room for Cams at a later date maybe

std gasket is 1.2mm

[Niall]

Well rep for you Cully. Ive just spent a while on ebay using the info you have provided here and ordered my self all the gaskets and seals i need. Lightened my wallet a fair amount!

[cully]

list of prices and where i have bought stuff

Carparts4less 1x 369545030 Elring Crankshaft Seal..............£5.99 free p&p
Carparts4less 1x 369545000 Elring Crankshaft Seal...............£9.72 free p&p
Carparts4less 2x 369545020 Elring Camshaft Seal ...............£9.58 free p&p
Ebay neatcarparts 1x pair GEAR BOX DIFF SEALS ..................£8.89 free p&p (listed as 405 G/box seal numbers cross refrence to 6-Box)
Ebay 306Breaker 1x GTI6 Cylinder Head Inlet Valve...............£13.50+£3.95p&p
Ebay Bagx6 CRANKSHAFT BEARING SEAL ............................£3.50 Free p&p
Ebay Bagx9 TB-Inlet Manafold Gasket...................................£4.00 +£2.30 Peugeot part 1635C3

[Piggy]

good work fella.

feels good to do the job well doesnt it?

[devils_fuel]

Well researched cully

I need to pick your brains...

[cully]

list continued
list of prices and where i have bought stuff

Parts ordered from Peugeot today £78.52
they gave me 10% discount off of servicebox prices thats why the prices in the list above are different from the ones below
head gasket will take 2 weeks as its got to come from France
Please remember this gasket is not the MLS gasket it is the 1.4 repair gasket listed for the XU10J4 engine and it is the soft type.
the rest of the stuff will be at the dealers on wednesday

Peugeot Head Gasket 1.4mm soft ...................................0209T9.....£47.95
Peugeot VALVE STEM SEAL ...................................X16....095638.....£20.05
COOLANT MANIFOLD GASKET DIAM 42 (back of block)....1339 83.....£1.38
ENGINE WATER THERMOSTAT GASKET ..........................1340 48 ...£1.00
ENGINE WATER HOUSING-Block SEAL ............................1340 33 ...£3.13
INLET MANIFOL GASKET ................................................0349 G1...£3.61
Rad hose O-rings....................................................X2....1343Z4.....£1.39


as far as im aware
outstanding things to get now are
assembly gasket paste
Exhust Gasket
and
bottom end bearings once ive stripped the block and inspected

[ginge191]

Doing well here mate! good job!!

[cully]

today drove to Exeter to pick up some of the gaskets and seals Peugeot ordered for me.
so now i can start reassembling the head

i have ground in the 16 valves so had to rewash the head to remove the grinding compounds then dried it and blew it through with air.

Now to fit the valve stem seals!

NOTE DON'T FORGET!!!!
the valve spring seat washers need to be fitted before the seals as the washers wont go over the seal!

with my scrap valve i ground the end to a point to enable me to use it as a guide for fitting things over the valve stem

   

insert valve into head,
slide spring seat over locate home with deep socket,
slide valve stem seal onto ground off valve end,
lightly tap seal home until the sound changes meaning it won't go on any farther

   

continue until you have done 16

   

now for the time consuming bit fitting the valves

insert correct ground clean valve
insert springs
place top washer over springs
compress with your valve spring compressor
making sure you have access to the valve top

   

Now for the fiddly bits fitting the Colet's to the valve head

TOP TIP
use a magnetic screw driver and some grease !

   

place the Colet's on the valve grove the grease will stick them

   

remove the spring compressor

   

valve cap should trap the Colet's nicely
to test they are seated place socket over the valve cap spring and hit it with a rubber hammer enough to force the valve open if the Colet's stay put on to the next one

[Scott]

Excellent progress, a very interesting read

[devils_fuel]

Oh I remember those days of rebuilding heads and this bloody collets - fun fun !!!

Loving the progress, a nice little project for the winter ready to slot in come the spring

[cully]

Followers installed

   

installed the cam carrier locating pegs 2 on each cam

   
   
   

to identify the exhust cam it has the drive slots and oil feed for the Vac pump

   

i have just loosely assembled this with no screws as i dont want to bend valves by moving it around the bench

   

also found some more seals that might be worth changing in the Vac pump
but peugeot only list the one seal not both

4556 05 O-RING SEAL DIAM 44X48-2

   

[Dum-Dum]

Not using assembly lube on the bearings?

[cully]

i have just loosely assembled this with no screws as i dont want to bend valves by moving it around the bench

meaning i have not finished assemling it yet reason is my head bolt tool wont go deep into the head enough with the cams installed

Not using assembly lube on the bearings?

No not yet on the cam bearing faces but have lubed up the buckets before inserting them

[Dum-Dum]

Sorry mate, you posted pictures so i didn't read words

[cully]

Block stripdown!
i do hope this helps someone
as i hope it helps me in putting it back together!

sump pan off

   
   

small crank enseal removal , oil sprocket is friction held not keyed

   

windage tray

   
   

bigend orentation marks

   

marks to camshaft on pistons

   

   
   
   

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main bearing 2 has the endfloat thrust bearings

   

   
   

oil spray bars are pointing at gudgion pin

   

   

[Niall]

Ive just been though all of that. Its all fun and games! Do you have a honing tool?

[cully]

blocks cleaned ready for some paint

   

   

have also been doing some reserch into ACL Race bearings for the bottom end

   

[nickroo]

Nice thread

[Dum-Dum]

Thats a seriously good job you've done of cleaning that block mate.

[cully]

have measured my jernals on the main and big ends
main bearing 59.95mm
conrod bearing 49.95mm

checking against the ACL Info
looks as if my crank is standard and not ground

so it looks like i need
mains ACL 5M1677 /STD (Duraglide)
conrod ACL 4B7700H /STD (Race Series)

   

[cully]

Glyco Bearing numbers

   

[Piggy]

Are you honing and replace piston rings??