The toy, 306GTI trackday racer. *Dial-up warning: Picture heavy*

[Janne L]

Shipment arrived from the UK, ACL race bearings for big ends and main bearings and the two missing inlet valves i was missing. So i finally got all valves lapped in and the head is now finally ready for a final clean and a light coat of paint before final assembly.

Made a to-do list, 29 points and counting, upwards, 'till it's road ready.

[jannelevenrot]

We're of for an adventure!


(ok, fine, we're of for a bath)

[connorp]

Looking good man, quality thread!!

[Janne L]

Daily report.
Block cleaned and painted, started honing a cylinder but it turns out I only have fine grit stones for my honing tool, need something rougher if I want the engine ready before my firstborn graduates uni...
Gearbox cleaned, primed and painted.
Inlet primed and painted.
Oil pan cleaned.
Front sub-frame wire brushed, seam welded all over and primed.
Wishbones stripped of bushings and ball joints.

Things go fast when you get help!


Work continues tomorrow.

[Janne L]

[7057sam]

Looks great

Definitely going to have some crazy colour scene going on underneath

[Janne L]

Love me some colour!

Mini update since I'll be working on larger engines than mine this weekend (14 litre V8 turbo diesel @625bhp)
The block is honed and all I need to start assembly of the bottom end is a set of piston rings. Also waiting for a large delivery of gaskets, lubricants and chassis components.

Finances got a punch in the nuts though, one of our furry family members has been signed in to hospital with pus/blood filling his thorax, the first day we saw costs passing £1500.
Insurance, loving it right now!

[7057sam]

Sorry to hear about your family situation mate

[Janne L]

Our fluffy friend pulled through, Happiness all around! [emoji1]

My hands are still itchy from wrapping the exhaust manifold this afternoon! But it only took an hour to do, from all the horror stories I've heard of I was prepared for a much more difficult job.


Still waiting for a whole bunch of parts for the engine, can't start putting it back together until they arrive, so in the meantime I'm painting anything I can get my hands on [emoji14]

[7057sam]

Looking great as always Janne

Very Tidy job on the exhaust mani

[Janne L]

10 week delivery time for the full gasket set... I'll need to figure something out, found the set I Germany so I might get it from there.
Going on a small road trip to visit my supplier of go fast stuff after work today, so I'll hopefully have something to write about soon.

[Janne L]

Removed PAS from the ram and replaced inner and outer ball joints with new units, huuuuge difference in stiffness!

[Janne L]

Started the day with an empty block and head and ended with a full block and head, good times :-D



I'm booked for a trackday on the 31st, I'll get the clutch on the 25th and I can't order my new master cylinder till the same day.. Gonna be tight!

---

Started the day with an empty block and head and ended with a full block and head, good times :-D



I'm booked for a trackday on the 31st, I'll get the clutch on the 25th and I can't order my new master cylinder till the same day.. Gonna be tight!

[Dum-Dum]

Gosh what a rebuild

[Janne L]

Got stuck at this stage, discovered that a previous owner (probably the same one who got the chip) has replaced the inlet cam pulley hub with one for the exhaust, which makes timing the cams up with pins impossible :-(
Hopefully I'll get the correct part delivered before the weekend so I can continue the assembly.

[Janne L]

Sunday update, while enjoying a cold lager at home after a day in the garage.
The engine is pretty much ready to drop in, I'll get the clutch tomorrow and hopefully be ready to drop the engine in on Wednesday or Thursday.




Hoping this will do the job, a bit lighter than a real tensioner [WHITE SMILING FACE]

[7057sam]

Is that braced booth sides ??

[Janne L]

Is that braced booth sides ??

No, hoping that the stiffness of the bottom bolt will keep the alternator lined up.

[welshpug]

inlet and exhaust pulleys and hubs are identical on the gti6 engine.

[Janne L]

inlet and exhaust pulleys and hubs are identical on the gti6 engine.

Not according to my documentation.

[welshpug]

looking at the wrong docs then!

[Janne L]

Peugeot workshop manual for the Xu10j4rs, should be correct, but I have to admit I never compared them side by side, only checked the markings and saw that they didn't match with what the manual said.

[welshpug]

never seen that,off what I've seen on every gti6 I have taken apart, and Servicebox, that the RS engines use two identical pulleys and hubs, but the J4R and XU7 use differing hubs.

the R inlet is the same as the RS but not the exhaust.

[Janne L]

My new pulleys, from a phase 2, are identical and have the same markings. Maybe it's a ph1 thing then?

[Janne L]

Yesterday's plan was to marry engine and gearbox, so naturally, after 5 hours in the garage, they are still no closer each other!
I did get some other stuff done though, mounted battery under the passenger seat, wired it up to a circuit breaker in the engine bay with a 25mm2 cable. Manufactured a mount to said breaker and welded it to the wheel well. Made new alternator and starter cables. Wired up an oil temperature sender. And fought for 20 minutes with getting the wiring loom for my wide band lambda sensor from engine bay to the hole left after the head unit. And I also improved a bit on my alternator mount.




Work continues today, 5 days to the season premiere!

[Dum-Dum]

Think I'd of mounted the kill switch closer to the battery and within your reach, between the seats or center console.

[Janne L]

I had trouble choosing a position myself, in the end I decided that since its not good to kill the switch while the engine is running I don't want it within reach from the drivers seat. In an emergency there will be the possibility of killing the switch via a pull handle in the grill.
In the future I'll probably get a master fuse that I'll put as close to the battery as possible.

[Janne L]

That feeling!



Married engine and transmission, mounted front beam to car, and finally got the engine inside the bay [emoji1]

4 days until the season premier.

[RetroPug]

Great progress!

[Janne L]

:-(


After pushing myself and my very, very helpful friend to the max for far too long we got it working, started up great and runs sooo nicely!
But, alas, I failed at getting the big crankshaft seal mounted properly, and this is the result.
For several reasons I don't have the strength mentally to keep at it for the time being, so I drove the car to another friend and mechanic who runs a workshop to get it fixed.
Hopefully it'll be ready in about a week or so.