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Thread: French Rebuild - Peugeot 205

  1. #1
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    Default French Rebuild - Peugeot 205

    HI every one,

    after 135k miles and around 19 years, I decided that the engine of my 205 should have a rebuild. She was still running ok, witness to that is the fact that 2 nights before I parked her in the garage, I drove her to Muree at night with a friend for a quick dinner.

    I had been planning this rebuild from 6 months, as the fuel consumption had gone up because of some loss in compression, and there was noticeable blow as well. Well keeping it short, the overhaul is undergoing.

    After being parked overnight, the experienced mechanic had the engine down the next morning, and by evening it was all in to bits n pieces. The observatoins were

    1- The pistons were all good, As oversize pistons are not available so the same ones will be fittd back,

    2- We had to put in Sleeves to make the bore standard sized again.

    3- New standard size rings (Made in Germany) had to be fitted back

    4- New standard size main big end and the connecting rod pieces(as mechanics call them) were required.

    5- the crank shaft was pretty much perfect, just some polishing required.

    6 water pump was pretty good as the car had a decent coolant running.

    7- nuthing happens to the oil pump

    8- we needed engine gasket set.

    9- new valve seals

    10- the valves and the valve guides were good, just to be polished

    11- the head did not require to be skimmed, as the car never overheated and the old headgasket was not blown.

    12 a genuiune 2 notch headgasket

    13- New timing belt kit (1 belt with 2 bearings)

    Unfortunately i lost some pictures of this stage, hence moving forward to the closing stages now.

    here is the list of work done/parts fitted

    1. Putting in sleeves The best quality available in pakistan, fitted to many pugs and running without problem for years in those cars.

    2- valves polishing and adjustment from kharadia

    3- cam polishing from kharadia

    4- head polishing

    5. lots and lots of kerosine oil for cleaning the engine and parts 3 to 4 times during all the stages.

    6- New engine rings

    7- crank and connecting rod pieces standard size,

    8- all the small gaskets ad seals

    9- THe headgasket, awaited

    10 - New Injection Nozzles

    11- New Clutch kit

    12- drive shaft seals

    13- and an oil filter and oil- yet to be out in..

    more pictures later, but here is where the engine is today.


    the block
    French Rebuild - Peugeot 205 -398897

    the head
    French Rebuild - Peugeot 205 -398898

    Do the environment a favour, Use less airconditioning .. and please walk to the shop to get a pack of cigarretes..its only a 3 min walk..

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    Thumbs up Very interesting!

    Quote Originally Posted by minex View Post
    @princeSultan

    I hav this car from 10 years , got it when it had only 23k miles on it, now its 135k miles. i know each and every part fitted during the last 1- years, the engine was running its original head gasket which was still good.. .i would hav been the last person on earth to thorw away this engine.. if it was any other 205 in town then i would hav put in any toyota engine as well.

    well All "They " say is ********... after 19 years and 220,000 kms, the car still had most parts which were fitted in the factory.. the engine only required oil changes with oil filter , diesel filter(once an year) , air filter (home made every other oil change), 1 water pump, and that is it...

    Clutch and pressure plate were change at 130,000 kms. THe car was not driven softly at all,

    The 205 is really a master piece of french engineering in the late 80s. still way better than the local market garbage.
    Bhai aap to IBNE BATOOTA ho kisi din josh ayea to Aaqib bhai 205 ko Paris hi le jaen ge by road!!! Yes, it's possible it can make it to Europe i guess

    Btw it's the best idea to keep this car until we get an honest leader as the head of state and hopefully auto makers like Renault, Peugeot, Hyundai, VW and Fiat start their business in Pakistan.

    Otherwise you know how much does a Swift (and Vitz) cost
    Safety 1st!
    Always Must!

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    Cool

    @ princeSultan

    to be honest these sort of cars are only for the geeks now, who can

    1- afford a downtime of several week
    2- Arrange parts from all over the world
    3- Can spend extra money on the car
    4- have the patience to go through this process
    5- know and have access to people who know the technical and professional expertese to carry this job..

    6- last but not the least, dont bother driving a car that looks around 20 year old.

    if you can do all of those.. then you get to the point where you get unimaginable pleasure from a car that is 20 year old and cost 1/3rd of the modern junk available..

    personally i dont blame anyone who drives a vitz or a swift or even a mehran.. They dont have the time and other factors.. and they dont bother driving those either.. it works for them.. they reach places as well

    and everybody drove happily ever after... lol
    Do the environment a favour, Use less airconditioning .. and please walk to the shop to get a pack of cigarretes..its only a 3 min walk..

  4. #23
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    Default

    Masha ALLAH.

    the 6 points you mentioned, agreed. it is very good to see that you are using quality replacement parts for the rebuild. loving the quality, waiting for the final outcome.

    Best of luck.
    Honda, Sony, AMD, Android, Grassroots, Hiwatt, Turtle, Dream Theater !

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    Quote Originally Posted by raging_ravin View Post
    Masha ALLAH.

    the 6 points you mentioned, agreed. it is very good to see that you are using quality replacement parts for the rebuild. loving the quality, waiting for the final outcome.

    Best of luck.
    +1
    But overall cost of the car still remain lower if we calculate everything for about 10 years use

    But not to mention how much KHWARI is there in such pleasure

    @minex
    Btw what was the fuel consumption? Was that around 15 kmpl?
    Safety 1st!
    Always Must!

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    Smile

    @raging_ravin

    thank you,

    The 2 headgaskets that you see in the picture are being sent back, because i dont like the quality, although they are OEM parts but I have ordered the genuine peugeot Headgasket , the top quality, the headgasket alone is costing around 14000 rupees. attached is the picture below.

    French Rebuild - Peugeot 205 -402363
    Do the environment a favour, Use less airconditioning .. and please walk to the shop to get a pack of cigarretes..its only a 3 min walk..

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    Smile

    @raging_ravin

    thank you,

    The 2 headgaskets that you see in the picture are being sent back, because i dont like the quality, although they are OEM parts but I have ordered the genuine peugeot Headgasket , the top quality, the headgasket alone is costing around 14000 rupees. attached is the picture below.

    French Rebuild - Peugeot 205 - 402363
    Do the environment a favour, Use less airconditioning .. and please walk to the shop to get a pack of cigarretes..its only a 3 min walk..

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    Default

    @Minex

    Good going Aqib (Y) I also remember lovely ride to Monal on this Beautifull Car.
    Exploring Machines is my Passion...

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    Quote Originally Posted by PrinceSultan View Post
    +1
    But overall cost of the car still remain lower if we calculate everything for about 10 years use

    But not to mention how much KHWARI is there in such pleasure

    @minex
    Btw what was the fuel consumption? Was that around 15 kmpl?
    agreed. its not about the cost anyway in my opinion, because the pleasure of driving the master piece will be enough to justify the cost.

    regarding khuwari, i think that khuwari is meant to be ! an enthusiast, whether of any interest, will do khuwari, majority or times for others, sometimes for himself too !

    Quote Originally Posted by minex View Post
    @raging_ravin

    thank you,

    The 2 headgaskets that you see in the picture are being sent back, because i dont like the quality, although they are OEM parts but I have ordered the genuine peugeot Headgasket , the top quality, the headgasket alone is costing around 14000 rupees. attached is the picture below.

    French Rebuild - Peugeot 205 - 402363
    it looks good in the pic though, but you know better. again, it is better to invest in something good once rather than multiple investments and waste of time. that genuine peugeot gasket will give you a strange peace of mind when you'll be driving it on your next trip to murree, nathia gali or may be karakoram highway

    keep updating, it is interesting. by the way this gasket was also ordered from europe, what made you critical of its quality ?
    Honda, Sony, AMD, Android, Grassroots, Hiwatt, Turtle, Dream Theater !

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    Default OEM parts quality

    @raging_ravin

    Yes they earlier headgaskets were ordered from europe as well, and the manufacturers are OEM suppliers to peugeot. But the parts which they supply to peugeot directly has to meet some very strict additional standards mostly and then the same product is sold with a peugeot stamp/name/packing by peugeot... where when the manufacturers sell the same part under their own brand, they mostly do not follow the additional standards and sell under their own name, I had all the 3 gaskets in front of me today, and the difference was obvious, the material used and the additional coating i guess high temperature silicone,, was pretty obvious.
    Do the environment a favour, Use less airconditioning .. and please walk to the shop to get a pack of cigarretes..its only a 3 min walk..

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    Default

    @imranbhatti

    thank you Imran bhai... will visit lahore very soon on it.. may be during or just after the running period.. hopefully within this month..
    Do the environment a favour, Use less airconditioning .. and please walk to the shop to get a pack of cigarretes..its only a 3 min walk..

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    Going along nicely!
    Nice, detailed thread.
    You have arranged some nice goodies for her.
    Its good to see someone taking care of a car which is quite rare in Pakistan and showing so much concern with the rebuild.
    One thing that is worrying me a bit is the sleeve stuff in the engine block.
    As per my knowledge this reduces the efficiency of an engine and results in over heating of an engine. (This might not be true in your case)
    Anyways wishing you luck with the rebuild.
    Hoping you will get it done in the best possible manner.
    One of the most difficult things in the world is to know how to do something, and to watch without comment, somebody else do it incorrectly.

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    Quote Originally Posted by minex View Post
    @raging_ravin

    Yes they earlier headgaskets were ordered from europe as well, and the manufacturers are OEM suppliers to peugeot. But the parts which they supply to peugeot directly has to meet some very strict additional standards mostly and then the same product is sold with a peugeot stamp/name/packing by peugeot... where when the manufacturers sell the same part under their own brand, they mostly do not follow the additional standards and sell under their own name, I had all the 3 gaskets in front of me today, and the difference was obvious, the material used and the additional coating i guess high temperature silicone,, was pretty obvious.
    nice analysis. its obvious. what is the update now, since you got the gasket.
    Honda, Sony, AMD, Android, Grassroots, Hiwatt, Turtle, Dream Theater !

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    After rebuild this engine last forever,is very durable engine and good handling of the car on the road.But the plastics of this car are not similar of the mechanic part.

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    Default Sleeves

    @daniyalahmad

    thanks for all your words, the normal perception about sleeves is not good, but there are so many factors in determining whether sleeves would work or not, we have put sleeves on around 100 engines, only a few troubled, we have discovered the best quality of sleeves, and in the past few engines, they have not troubled even after 5 years of use,

    the main reason of trouble are quality of rings and sleeves, and the headgasket thickness not being according to the skimming of the head..

    in my case i have put in top quality sleeves, top quailty german rings, original peugeot headgasket , the same thickness which was fitted to the engine when it left the factory.. and the head has not been skimmed, so there shudnt be any problems,..

    The idle running and initial running period also is an important factor.
    Do the environment a favour, Use less airconditioning .. and please walk to the shop to get a pack of cigarretes..its only a 3 min walk..

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    Default its purring now...

    @raging_ravin

    its running now.. will post vdos soon

    Yesterday(Sunday Evening) evening we cranked the engine outside and kept it running for around 45 seconds.. MashAllah there were no problems,.

    the engine was fit back in engine bay.. and today gave it an idle running of an hour.. I am going to the workshop to pay a visit..


    French Rebuild - Peugeot 205 -404815
    Do the environment a favour, Use less airconditioning .. and please walk to the shop to get a pack of cigarretes..its only a 3 min walk..

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    Masha ALLAH.

    looks nice and clean, the gear box is super clean though

    what is a kharadia by the way ?
    Honda, Sony, AMD, Android, Grassroots, Hiwatt, Turtle, Dream Theater !

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    Quote Originally Posted by minex View Post
    @daniyalahmad

    thanks for all your words, the normal perception about sleeves is not good, but there are so many factors in determining whether sleeves would work or not, we have put sleeves on around 100 engines, only a few troubled, we have discovered the best quality of sleeves, and in the past few engines, they have not troubled even after 5 years of use,

    the main reason of trouble are quality of rings and sleeves, and the headgasket thickness not being according to the skimming of the head..

    in my case i have put in top quality sleeves, top quailty german rings, original peugeot headgasket , the same thickness which was fitted to the engine when it left the factory.. and the head has not been skimmed, so there shudnt be any problems,..

    The idle running and initial running period also is an important factor.
    Hmmm...
    Thankyou for the explanation.
    A close friend had some bad experiences with the sleeve stuff in his vehicle so I had that in mind.
    Anyways keep up the good work, hoping to see the car performing to its fullest soon!

    Quote Originally Posted by raging_ravin View Post
    what is a kharadia by the way ?
    He is the dude who does the bore, sleeve, installation of valve guides etc in an engine.
    One of the most difficult things in the world is to know how to do something, and to watch without comment, somebody else do it incorrectly.

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    Default

    @Minex

    See u then Insha Allah.
    Exploring Machines is my Passion...

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    Smile More Genuine new parts

    Injector Nozzles by Lucas -
    French Rebuild - Peugeot 205 -405869

    New drive shaft seals

    French Rebuild - Peugeot 205 -405870

    track rod ends

    French Rebuild - Peugeot 205 -405871 French Rebuild - Peugeot 205 -405872
    Do the environment a favour, Use less airconditioning .. and please walk to the shop to get a pack of cigarretes..its only a 3 min walk..

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    Default Engine going back inside

    French Rebuild - Peugeot 205 -405873
    Do the environment a favour, Use less airconditioning .. and please walk to the shop to get a pack of cigarretes..its only a 3 min walk..

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