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Forums › Tuning, Modification & Legal › Project Cars › Blue Jay Way: Sim's GTi 180 "Back to Life"


 
 

Blue Jay Way: Sim's GTi 180 "Back to Life"
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Sim
PostPosted: Wed Aug 10, 2016 7:12 am Up
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Joined: Jun 20, 2012
Posts: 887
Trade Rating: 0
Location: Bristol


Greetings!

Been meaning to start a project thread as soon as I got the car -- nearly a year ago! Shocked better later than later than that Wink

September 2015
Together with mates started looking for a place to work on cars, so it was time to find myself a project.
Being very happy with me 2litre diesel, seemed like a good idea to try out petrol as well, and how can a 206 nut miss the top of the range one Smile

This happily came up just half-an-hour away! 109k being a bit of a mileage but sporting great potential and that Scorpion system Smile Airbag+ABS/ESP faults and a fallen-off rear view mirror arrived at a bargain value (or so I thought Razz )
 


Had to keep him SORNed on the lawn for several weeks...
 

...but couldn't bear to see all of the moisture and slugs creeping up, so swapped them places. Then the daily ride began to plough through the lawn and few months down it became a mud bath (to all those with a bit of gardener in you: the grass has cured by now) Very Happy
 


October 2015
Jay got his faults read with PP2000, you'll read below when I set out to hunt those down.
Started working on that car barn, and went to the Crazy Golf 206info meet Smile

November 2015
On a crammed driveway replacing Jude's wishbones Very Happy dreaming about the day of having a sizeable workshop
 


December 2015
Had enough muddling the lawn, did the MOT trick and drove Blue Jay to the unit. First a touch of soap
 

(sticker isn't mine, honest Cool )

They do stand out in white! Did you know that Mr Muscle's oven cleaner is the best and cheapest product to clean the alloys? Wink
 


One fine day I'll sort you out Twisted Evil
 


It was the first journey on the motorway, man this car is awesome! Even after seemingly having been power-driven in the past (no surprise for a GTi), still went like stink! Happily reached the dry storage for some time
 


January 2016
Jude was due for her MOT: passenger airbag light, rattling rear axle, and clutch on its way out -- quick fixing any of those wasn't an option. Combined with desire to put Jay on road took the better of me, and so the works started.

Firstly there was no power arriving to the horn itself via connector -- taking it apart showed green-oxidised terminals. Contact spray and some scrub sorted that, but it still wouldn't horn when pressing on the airbag. Read on Smile

Brake pedal would spongily travel all the way to the floor (efficiency though mildly affected), no wonder why
 

Quickfix attempt to weld a nut, kept eating more and more of that seemingly cross-threaded bleeding nipple
 

 

Sourced the whole caliper from the land of sporty Pugs, will go in at a better day, and the naughty old one will get some boring.

MFD kept coming up with "Airbag fault" and "ESP/ASR not functioning" since the day I got the car, relevant faults read with PP2000 back in October were as follows:
  • Airbag ECU:
    • Permanent fault. Level of driver module trigger 1. Short circuit .
    • Permanent fault. Level of driver module trigger 2. Open circuit.
    • Intermittent fault. Supply voltage.
    • Remote intermittent fault. VAN network.
    • Remote intermittent fault. Vehicle speed information.
  • ABS or ESP ECU:
    • Permanent fault. Flywheel angle sensor. Coherence.
    • Permanent fault. Flywheel angle sensor. Internal.
    • Remote permanent fault. Flywheel angle sensor. Incorrect value received.
Got me all worried that some of those errors will remain even after I get an unscathed COM2000 stalks unit. Barely anything was left of the old one (no airbag/horn ribbons, couldn't switch full beam on, ESP steering position sensor ring shattered; I heard from Pezhdi that such cases happen often after e.g. a quick job to fit bosskit) Sad
 

Wrote down serial numbers and sourced an £80 cheapo from 807 HDi breakers, arrived mint and with cruise control stalk!
 


Airbag lights and faults went away, horn and high beam came back! But ABS/ESP error was still on the dash... In despair, I started looking for the flywheel angle sensor replacement, but to have the COM2000 swap complete, I had to re-calibrate steering wheel sensor.
Done that via PP2000, drove some few meters in a straight line, and ..... VOILÀ! All ABS/ESP faults had gone; good job I didn't go down the flywheel sensor route Smile Happy days Very Happy
A bit misleading them faults though..!

Unsure by what forces of nature this has popped out of its socket in the car's previous life
 

Could be closely related to the fact that the front was dropped so low on coilovers, even tyres would shred them plastic arch linings on full lock, and previous keepers wouldn't do anything about that Sad
 

I've set coilovers to a reasonable ride height, got healthy wide arch liners from the same pugperformancemotorsport (hard-ish to come about otherwise), and yet it was still a pig of a job to put new droplinks, without fiddling in various ways to jack suspension parts
 


Never nice to find a snapped off cat heatshield, held by cables.. But better than hanging by a thread I guess Smile
 

No wonder it snapped -- an oversized cat back coupler pipe had been fitted some time ago, warping from the heat, leaving a cavity for the exhaust to blow through up against sink welds and Scorp's resonator (imagine that horrid rasp exhaust sound too, the first thing on the list to fix once I'm properly at it)
 

Even stock cat's downpipe bulge-deformed from all that pressure...

New paira shoes at the rear! (replacing cord-exposed oldies, this car seemingly had a lot of handbrake-turned fun)
 


And lastly, having donated a few bulbs by Jude, Jay was ready for the MOT!
 


February 2016
Yet it failed Evil or Very Mad
Rear view mirror was in the glovebox, and I thought it's ok to keep it there for a while, since MOT requires TWO mirrors to be on the car. However, there is a clause, that one of those two HAS to be the rear view grr Very Happy

Time was running out, but when you're glueing metal to glass, ensure not to rush Wink and hopefully not during winter, otherwise you need to keep windscreen warm for the best adhesion (I used hair dryer, but one more heat lamp from outside would've helped better)
Also ensure you clean the old glue bits properly, use a mono blade and acetone
 

 

 


So MOT passed with flying colour numbers (on emissions Very Happy ) made me a proud GTi 180 owner and daily rider. Since we've been mainly working on the unit, I'd done only a minor mod: MrWhite's keyfob conversion (received not as embossy pictured on ebay, oh well), holds to-date!
 

But look at that appalling logo! Ugh! Thinking of transplanting one from the original key, will need to nicely carve/mould the plastic out though

April 2016
Brought another EW10J4S from Pezhdi (cheers buddy!), clocked in at 79k miles, will be a good candidate for replacement and generic study of these beastie lumps Smile
 


June 2016
Noticed excessive camber on O/S/R wheel (actually, I should thank them muddy roads around the unit -- made me hear the dirt-stuck tyre scraping the inside arches), and decided to immediately stop driving the poor car.
Good job I got given this Jag away for nothing, quickly put it back on the road, happy for now (2400mm and 3000mm lengthy building materials fit into it perfectly -- brings the completion of our unit quicker Smile )
 



Arrghhhh can't wait to get back to me Pugs!



An exhaustive TODO list (pun intended):
☐ sort out Scorpion <-> cat coupler, so it stops rasp-blowing through and through
☐ inspect headlights wiring: due to some aftermarket headlights wired in the past, the dipped beam of stock crystals always stays on, even when the stalk is at the "off" position (except side-lights), no matter the if light sensor is enabled or not!
☐ rear axle rattling like hell and packing up (O/S/R wheel has so much camber that is about to start rubbing against the arch due to excessively worn out rear axle's trailing arm bush, seen clearly by manually rocking the jacked up wheel). Plans are to take it apart and see how bad a damage is, came worst just get a recon one
☐ shuddering/pulsating-grinding noise coming somewhere from the cambelt when engine cold, need to localise the problem using stethoscope; possible cambelt change pending (couple of related 206info threads here and here)
☐ inspect exhaust manifold: rattling/popping/beans-boiling noise on bends during engine/chassis flex suggests loose manifold bolts/cracked welds, since a thorough suspension check didn't reveal any causes for such
☐ another massive rattle at ~4k RPMs, for now I blame the rasp
☐ remove rolled-up felt from the seats to look like new (using lint shaver)
☐ bodywork patchups, alloys refurb, machine polish through and through
☐ exterior mods, brainstorming in progress Smile
☐ finish the build of garage workshop first to finally start work on cars! Very Happy

DONE:
☑ put back missing nut from the exhaust manifold heat shield (caused in massive rattle at 2k)
☑ got SP bonnet vents, waiting to go in

2.0 HDi, year 2000 (daily)
GTi 180, year 2004 (garaged)
Missus' 1.6 16v CC, year 2007 (garaged)
Ex-cars:
Jag X-Type 2.5 V6 AWD, year 2002
Jag S-Type 3.0 V6 RWD, year 2000 (still at my folks)
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Edward
PostPosted: Wed Aug 10, 2016 4:02 pm Up
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Joined: Feb 08, 2010
Posts: 6968
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Location: In the garage


Sometimes I think it would be good to buy a standard Gti 180 but if the others have little problems like yours has it puts me off!
2001 GTi 138, Bilstein Sprint dampers, H&R springs, 21mm Peugeot Sport torsion bars, 22mm rear ARB, Peugeot Sport Group A wishbones, 283mm discs, Goodridge stainless hoses, Maniflow 304 grade 4-2-1 2.5" manifold and system, 200 cell cat, Richard Longman head, 45mm Jenvey throttle bodies, 9.5mm TB spacers, 90mm air horns, Jenvey throttle linkage, Jenvey fuel rail, Aeromotive and Goodridge fuel fittings and braided hose, ITG sausage filter, Radtec custom radiator, Piper Ultimate Road cams, Piper vernier pulleys, Omex 600 ECU. Saxo electric PAS pump, Vibra Technics engine mounts. Samco coolant hoses, TTV steel flywheel, 4.76 final drive ratio. 2013 Volkswagen CC GT 2.0 TSi. 2013 mercedes B180
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Sim
PostPosted: Wed Aug 10, 2016 5:56 pm Up
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Joined: Jun 20, 2012
Posts: 887
Trade Rating: 0
Location: Bristol


No wonder it's a project Wink high mileage and had a couple of boy racers in its past by the looks of it.

I got it for £700, it's probably worth £600 as they still tend to keep their price, even ragged ones.

If you want a looked-after/decent one, they go about £1000-1500 these days.

2.0 HDi, year 2000 (daily)
GTi 180, year 2004 (garaged)
Missus' 1.6 16v CC, year 2007 (garaged)
Ex-cars:
Jag X-Type 2.5 V6 AWD, year 2002
Jag S-Type 3.0 V6 RWD, year 2000 (still at my folks)
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David1156
PostPosted: Thu Aug 11, 2016 4:48 pm Up
Loving the 206 Experience


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Joined: Dec 26, 2013
Posts: 322
Trade Rating: +1
Location: East London


Looks like the 180 has kept you busy! Very Happy Masked headlights and fogs are a must imo, they give the car a so much more aggressive look. Any plans for putting a turbo or ITBs on the spare engine? Wink
Current: Albi Blue Clio 197
Previous: EZR 1.1 206 Zest 3 5dr
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Sim
PostPosted: Mon Aug 15, 2016 4:33 pm Up
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Posts: 887
Trade Rating: 0
Location: Bristol


Cheers David! Not as busy as the unit has (I sometimes wonder where my project would be, had all the time and money gone into the Pug instead), but things are to change for the better Smile

Good idea on masking them lights and fogs, got a few spare, won't be a loss to cook some in the oven
Then long term plans would be to get some Angel Eyes and make them actually shine Very Happy (maybe drill some xenons within the rings), will see once I source some shoddy Angels to play with Smile

2.0 HDi, year 2000 (daily)
GTi 180, year 2004 (garaged)
Missus' 1.6 16v CC, year 2007 (garaged)
Ex-cars:
Jag X-Type 2.5 V6 AWD, year 2002
Jag S-Type 3.0 V6 RWD, year 2000 (still at my folks)
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MrWhite
PostPosted: Tue Aug 16, 2016 7:30 pm Up
Loving the 206 Experience


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Joined: Mar 23, 2014
Posts: 304
Trade Rating: 0


i have some angels sim with 10k Hids if you want them inbox me £80 Wink also ill send you some pics of Merlot and my new project if your on the Facebook
My 206 Project Thread
 
 
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Sim
PostPosted: Wed Aug 17, 2016 11:00 pm Up
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Joined: Jun 20, 2012
Posts: 887
Trade Rating: 0
Location: Bristol


Hey Mate! Wink Good to hear Pugs are keeping you busy too Smile

Thanks for the offer! I reckon your Angel Eyes are black Cool and yet I'm after silver ones. How about you sell them to good hands, and we'll instead write up a "How to.. make some actual HID Angel-Lights-the-road", as I'm curious in the DIY bit Very Happy Such post would then become a great piece of info for any future 206 owners Smile

2.0 HDi, year 2000 (daily)
GTi 180, year 2004 (garaged)
Missus' 1.6 16v CC, year 2007 (garaged)
Ex-cars:
Jag X-Type 2.5 V6 AWD, year 2002
Jag S-Type 3.0 V6 RWD, year 2000 (still at my folks)
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pAvax
PostPosted: Thu Aug 18, 2016 5:31 am Up
Full on 206 Owner


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Joined: Aug 01, 2016
Posts: 248
Trade Rating: 0
Location: Essex


Sim, my brother and I are looking into this as well. If we find the best approach without cutting the loom, will post here a how-to as well. Would be nice to give people some different options.
Current project: Ciri
Silver 206cc - 2.0 - 2001
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VorTechS
PostPosted: Thu Aug 18, 2016 1:03 pm Up
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Joined: Feb 08, 2010
Posts: 2217
Trade Rating: +15
Location: Gloucestershire, UK


No wonder you are spending so much time at the Unit! That's one heck of a list to be getting on with!
 

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MrWhite
PostPosted: Thu Aug 18, 2016 10:11 pm Up
Loving the 206 Experience


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Posts: 304
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I dont need Halos anymore now I have these Sim. what do you think?

Nates 206 Merlot

My 206 Project Thread
 
 
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Sim
PostPosted: Sat Aug 20, 2016 9:50 am Up
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Posts: 887
Trade Rating: 0
Location: Bristol


pAvax wrote:
Sim, my brother and I are looking into this as well. If we find the best approach without cutting the loom, will post here a how-to as well. Would be nice to give people some different options.
Looking forward to your findings!

Could you post some pics as you go (actually that's worth a separate project thead, just like Shadowstalke did for his Ouragans ;), even if you do need to cut the loom?
I'm curious what clearances there are and bulb/HID/projector locations/sizes. Will be able to see the level of tinkering it will be about Smile

MrWhite, how did you do yours?

2.0 HDi, year 2000 (daily)
GTi 180, year 2004 (garaged)
Missus' 1.6 16v CC, year 2007 (garaged)
Ex-cars:
Jag X-Type 2.5 V6 AWD, year 2002
Jag S-Type 3.0 V6 RWD, year 2000 (still at my folks)
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Sim
PostPosted: Sat Aug 20, 2016 9:53 am Up
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Joined: Jun 20, 2012
Posts: 887
Trade Rating: 0
Location: Bristol


VorTechS wrote:
No wonder you are spending so much time at the Unit! That's one heck of a list to be getting on with!
We sometomes motivate each other whilst building that neverending nonsense mansion, that only a nicely done workshop provides the best car tinkering environment you want to keep coming back to Very Happy

2.0 HDi, year 2000 (daily)
GTi 180, year 2004 (garaged)
Missus' 1.6 16v CC, year 2007 (garaged)
Ex-cars:
Jag X-Type 2.5 V6 AWD, year 2002
Jag S-Type 3.0 V6 RWD, year 2000 (still at my folks)
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Sim
PostPosted: Sat Aug 20, 2016 9:54 am Up
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Joined: Jun 20, 2012
Posts: 887
Trade Rating: 0
Location: Bristol


MrWhite wrote:
I dont need Halos anymore now I have these Sim. what do you think?

Nates 206 Merlot
Looks proper evil! Can set to match your mood any day Very Happy And with proper tweaks, Merlot could grow a middle name Cool
 

2.0 HDi, year 2000 (daily)
GTi 180, year 2004 (garaged)
Missus' 1.6 16v CC, year 2007 (garaged)
Ex-cars:
Jag X-Type 2.5 V6 AWD, year 2002
Jag S-Type 3.0 V6 RWD, year 2000 (still at my folks)
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