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'sloppy jaloppy' the 1.4hdi
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old-muggins

Posted: Thu Apr 02, 2015 7:52 pm

Joined: Nov 21, 2012
Posts: 38
Trade Rating: 0

Hi all,

Thought id finally make a project thread as this little 206 has been and still a project.. unintentional i'd like to add! Laughing

.

this thread will also serve as a 'record' of when jobs have been done and also anything i do etc could be of help to anyone else too.

We bought this little 206 1.4hdi 2002 plater in december 2014 in part ex with our old china blue 306 cabby se. bought the 206 with intentions of saving money on fuel and tax as the time it was costing approx 300 a month in fuel alone in the cabriolet.

We were also due to move out and being a week before christmas money was tight. So.. for 1,000 the the 206 was ours. We went back a few days later to swap the cars and paythe rest off. when we looked round it i noticed a few little jobs but didnt see it as a problem.
We had owned the car for around a week and along with a few little rattles and bangs as to be expected from a 12 year old car with 97k miles on the clock i figured id get them done over time.
in the first week while traveling up hill and accelerating the clutch began slipping.

I phoned the dealer and they arranged to sort the clutch problem,

Following week the rear axle was massicely knackered! drivers side radius arm was all over the shop! So another axle was ordered.

Here is a list of what has been done so far...

New clutch kit fitted at 98k
rear axle replacement 99k,

when rear axle was taken off all the bolts from the mounting bolts to suspension damber bolts, brake drum backing plate bolts (4 torx) and a few others i cant remember were cleaned up with a drill and copper grease applied on reassembly. For future if anything needs doing the bolts wont be a pig to budge Idea

silly after market wheels and spacers were quickly taken out of the picture and replaced with standard steel wheels.
A new brake valve compensator and rear wheel cylinders were also fitted.
Front drop links also replaced.

a few "add on" bits i was going to leave till last but have now been done through eagerness lol!

My LX model had rain sensor and light sensor however came with the single line display unit i.e clock and temp only.
I wanted to keep the auto rain and headlight feature but also fit the bigger multi-function display unit for mpg and range readout etc.
( makes sense having something Like that fitted in a car aimed at total economy I think).
So i popped the end off my wiper stalk and messed about inside the little hole and bingo my temp.and clock switched. so went ahead and fitted a bigger mfd screen found in a breakers yard along with the same steering wheel just in much better condition so took that too!
Fitted the screen and messed inside the stalk and the screen cycled through the mpg and range etc! Great news! A fella can never have too many gadgets haha.

To cut a long story short at this part... in taking off my original steering wheel i noticed the solder had broken on one of the terminals inside the grey plug that comes out of the coms2000 unit. Not wanting to solder the thing up for resistance reasons and such lark, i just figured it would be easier to replace the coms2000 unit anyway.

So.. off to the breakers again with my old coms unit in hand to compare and in the end the solution was the this..

*tip*

I couldnt find a coms unit with auto on the indicator stalk for the auto headlights, meaning it didnt have the button in end the of the stalk either. I couldnt find a comsunit that also had auto written on the wiper stalk for auto wiper position even more so with the two small arrows for the mpg and range etc.
the solution was... find a basic basic model 206 that was also multiplexed version and remove the coms unit and check the colour of the plug sockets and also how many pins it had. Checked against my old unit and bingo!
This coms unit from the breakers yard did not have auto written on the stalks so was not made for auto headlights or wipers.
I already had the push button for the auto headlight feature from my old coms unit which i could and fid swap over into the basic indicator stalk.
I also robbed a picasso sx of its push button on the drivers side for use in the basic coms unit taken from the breakers yard too.

The coms unit fitted and airbag and wheel fitted etc. The coms unit not only worked and subsequently turned the airbag warning light fault off, i still also have auto headlights and wipers! And now have the button for cycling through the mpg and range on the mfd too. All from a basic coms2000 unit. Result!! Places i found wanted much more just because my car had auto headlights and wipers.. not the fact you can just swapped the ends of the stalks from none button to buttons in 2 seconds but they also work and places cant charge as much either. I got my unit for 30 quid!

jobs left to be done...
cambelt,waterpump,crankshaftpulley etc.
Lower rear engine mount
replace exhaust and cat
Service
small patch of welding on drivers sill
clean underside with a drill, replace all rubber caps on floorpan and begin rust prevention.
remove interior, clean floorpan and spray clear waxoyl on floorpan for added protection against rust
remove bonnet sound deadening and apply double sided tape to help keep material from rubbing on power steering pipework
a small piece of paintwork needed on passenger side rear arch.
Replace handbrake cables

rust prevention method used*
when the axle was removed i drill cleaned the entire boot floor and axle space and applied kurust, Llowed time to dry, applied x3 coats of zinc primer, 3 coats of hammerite black stone chip.

The complete method for the entire underside including arches and outer sill ( to the small indentation line thst runs along the lower half of the sill). Is..
kurust, 3 coats of zinc primer, 3 coats of stonechip, 3 coats of waxoyl! And then for hught traffic area'•s i.e outter sills, chassic rails, leading perameters of the floorpan, sills, boot floor go one step further euth clear wax spray. The same clear wax spray thst will also be sprayed insde the cavaties i.e where the black bung caps are placed. The bungs will be replaced afterwards.

Every year after this initial rust prevention has been completed, i plan to was the underside once a month at least and every september get underneath and apply another coat of waxoyl. To top up the protection. Also this rule can apply tp sills and the arches too.

Finally...
good polish, replace washer jets and wipers.

Would like to say done but.... there's bound to be something! Laughing

Its now done 5k miles since december and despute the clutch and axle issue it hasnt been too bad really.

In some respects, im glad the car needs the jobs doing now.... rather than later and doing the work myself ( bar the cambelt) i know everything hss received the full attention such as any removed bolts have been cleaned up with a drill and liberal amounts of copper grease applied so they will come out easily in the future. im also hoping with all this work done, it wont need anything for the 3-5 years at least. given the exceptions of engine servicing, brake pads and discs etc, bulbs and fuses. And the oddities i.e anything at random that you could get with a much newer car i.e power steering leak or something. Im leaving exceptions for those but on the whole ither than routine servicing it will want for nothing from one cambelt to the other ideally.

It now stands at 102k miles and will be getting the above jobs done within the comes or months.

I have already managed "just!" Lol 734 miles from a completely brimmed tank to the needle being inline with bottom read line of the reserve fuel box marker.
That was steady 55mph on the motorway driving really steady and hopefully this 'may' imorove further after the work has been completed and the use of millers diesel ecomax in use too.

Ill update in due course and post pics as i go for this thread.

thanks
muggins

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