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Old 25-07-2012, 09:43 PM   #1501
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Been busy chucking bits at the car today. J4 inlet back on. Standard radiator and hoses refitted. Loom partially installed. Looks like I keep my wiring going through the bulkhead too which is cool.

This is the loom that i've bought, which I assume is from a 2000 reg car or something as the plugs aren't the same as the Rallye.

Can I just splice this plug direct to the multiplug with only two wires in the Rallye? From memory these wires are just for the oil warning lights.



This looks like I need a MAP sensor with a different plug from from the older 16vs



Same for the reverse switch?

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Old 25-07-2012, 11:07 PM   #1502
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Is that a single-plug GTi loom? Or VTS? It does have the later plugs for the MAP sensor and reverse light switch, but it looks different to the crossover ~2000-reg VTS loom I used on my VTS.

The plug in the first picture, isn't that the fuel cut-off switch? I seem to remember that GTi had it as part of the engine loom but VTS had it as part of the car loom. Or it might have been the other way round.

I've got a few of the later reverse light switches I think.

A mate of mine is selling a complete 69k miles 2000-reg VTS engine. 2-prong head, 130bhp out of the box (allegedly...). Problem is that he is up near Glasgow. They respond very well to the usual filter, manifold and exhaust, so you can have a bit of poke for not a lot of cash without having to fit cams and the associated expense of mapping.
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Old 26-07-2012, 07:34 AM   #1503
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I assumed it was a Peugeot loom but I guess it could be from a VTS. Why do I feel this isn't going to be plug and play.

The fuel cut off is part of the car loom on the Gti/Rallye. Whatever it connects to needs to be near the multiplugs so I think it must be a replacement for the other multiplug.
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Old 26-07-2012, 08:46 PM   #1504
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Found this picture from when I converted the 8v loom. The multiplug at the top only has three wires which are for the oil pressure switch and the oil level sensor.

Which just so happens to be the same number of wires as this other plug on my new loom.

Coincidence? Methinks not! Suppose I should probably buzz the wires to save blowing something up.





This looks like the MAP sensor I need

http://www.ebay.co.uk/itm/106-1-4-GT...item41523a12c7

and this the reverse switch. Simples!

http://www.ebay.co.uk/itm/Peugeot-Re...item3f199972e4
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Old 11-08-2012, 07:44 PM   #1505
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Well it turns out the single plug loom I bought is indeed a single plug loom, but for a 98-00 Saxo VTS. Which means literally zero pins match up with the Rallye car loom. D'oh!

Mankee pointed me in the direction of a dirt cheap Gti lump complete with everything bar the gearbox, including most importantly a single plug 98 Gti loom which is plug and play. Who ends an auction at 16:00 on a Thursday?? Thankfully for me someone did so the engine was mine for the princely sum of 102.51.

It had been sat for a while, but seemingly stored indoors. Mankee kindly volunteered/was coerced into giving me hand picking it up today(5:30 am start, ouch!).

Looking at it, it's covered in oil on the front of the block which makes me think the head gasket is leaking on the front left hand side over the alternator.

We whipped off the cam covers and they still have the original rubber seals which indicates they haven't been off too often. The cambelt pullies have been marked L and R which makes me think the belt has been done (The engine is apparently on 80k so that would tie with a 60/70k cambelt change). Spark plugs are some very new looking NGKs with an even brown colouring across the four.

I'm very tempted to just lob it in but i'd rather work on it off the car so I think I best do the head gasket now, will also do the belt, pullies and water pump whilst it's apart.

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Old 11-08-2012, 08:01 PM   #1506
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Good choice! Sounds like a bargain for 100, and it's so much easier to do everything (except a sump change!) with it on the floor.
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Old 11-08-2012, 08:11 PM   #1507
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Nice one.
5:30 start on a saturday- I miss them as I've not bought a car item for a while!!
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Old 11-08-2012, 08:25 PM   #1508
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Nice one.
5:30 start on a saturday- I miss them as I've not bought a car item for a while!!
Haha! Yup, me either. It's like a mini Christmas. I need to be careful and not get carried away now that i've got the kit car fund sat there.
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Old 11-08-2012, 08:31 PM   #1509
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Any thoughts on when you might be starting the kit? Presumably when the Rallye's back to normal road-going status?
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Old 11-08-2012, 09:15 PM   #1510
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Any thoughts on when you might be starting the kit? Presumably when the Rallye's back to normal road-going status?
The Rallye's not important to the kit car plan really, well other than funding it. Low comp engine needs to come out as there is a fair amount of money tied up in that. The Rallye isn't a daily driver so there's no real rush to get it back together, just want to do it cheaply and with a few trick bits where possible.

What is important is a garage. Hoping to buy a house after Christmas and that will be a big factor.

Currently fancying a Caterham over a Fury or Phoenix at the moment. When I priced up the bits for a new build Fury or Phoenix I got to near 8k without the engine, brakes, bodywork and a few other fairly pricey bits. I can get an ex Caterham Graduate race car that's road legal for circa 10k-11k. Tempted to by the prospect of running around for a season before ripping the engine out for BEC time. Needless to say I need to save, a lot!
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Old 12-08-2012, 12:12 AM   #1511
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I cannot believe how much that bastard engine weighed. Hooray for the chain and bit of tree we used.

Finished reading those "50 Shades of Grey for car g33ks" mags yet?
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Old 12-08-2012, 12:29 PM   #1512
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I cannot believe how much that bastard engine weighed. Hooray for the chain and bit of tree we used.

Finished reading those "50 Shades of Grey for car g33ks" mags yet?
Haha! Inspired thinking that. I'll save 50 Shades of Caterham for bed time reading.

Got the standard inlet back on today along with the standard injectors, throttle body. Also converted the fuel lines back from the dead end C2 rail to the straight through J4 rail, refitted the radiator fan and connected up the loom.

Sorry for the terrible picture, my iphone seems to dislike bright sunlight.

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Old 12-08-2012, 02:15 PM   #1513
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I think a Caterham will retain it's value. Not something to think about at this time, but it should be considered.

The MK's go very well on track, as developed by Danny Keenan in North West Sports................
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Old 12-08-2012, 04:22 PM   #1514
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I think a Caterham will retain it's value. Not something to think about at this time, but it should be considered.

The MK's go very well on track, as developed by Danny Keenan in North West Sports................
Browsing the classifieds the Caterham's retain their value extremely well. There are 20 year on cars around at the 10k mark.

Both the MNRs and MKs look good, but if I go open wheel i'd want to go Caterham.

Thanks to whoever changed my title btw lol

Fuel pump primes, big relay under ecu clicks but no spark and seemingly no fuel.

I checked the spark with a spare spark plug earthed to the chassis - nothing.

Only guessing RE fuel but there is no smell of fuel from the inlet which i'd normally expect with constant cranking.

Sounds like classic locked ecu right?
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Old 12-08-2012, 04:58 PM   #1515
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I *think* I've still got my ECU which I *think* is unlocked.
You want me to send it down to try?
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Old 12-08-2012, 05:20 PM   #1516
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I *think* I've still got my ECU which I *think* is unlocked.
You want me to send it down to try?
Cheers for the offer Mike. Might just take you up on that. I've actually got two ecus but they both appear to be locked. One of which was sold as "unlocked"

Going to see how much unlocking costs as I'd prefer a properly unlocked ecu.
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Old 13-08-2012, 01:47 PM   #1517
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I typed in "Caterham Academy" on here and this was one of the few threads that came up:

http://www.106rallyeforum.com/forum2008/showthread.php?t=58870

My pal Smithy, the 500+bhp Hayabusa drag racer who lives not far from where your engine is living can unlock ECUs properly by opening them up and having a fiddle. Shall I ask him for a price? Wouldn't mind another perve at his bike again as it's probably changed a lot recently.

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Old 14-08-2012, 11:13 PM   #1518
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Two questions:

1: I assume if the crank sensor or wiring was duff I would still get fuel through? Noticed today that the wiring was frayed and possibly shorting at the plug so i've sorted that.

2: 16v engine is semi sequential injection so three wires at the injector/main loom plug as opposed to the batch injection (two wires) of the 8v right?
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Old 15-08-2012, 08:20 AM   #1519
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Not sure about the injectors, but the crank sensor will definitely stop it starting, it's probably the most crucial sensor in the whole shebang.
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Old 25-08-2012, 08:05 PM   #1520
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Mike kindly posted me his spare ecu to help trouble shoot the Rallye.

Result = fired up first time! Tad loud without an exhaust though. Lol

Curl's Pugsport is waiting for me at my parent's house so i'll pick that up this weekend. Still searching for that elusive Rallye interior before I can get it back on the road though.

Also on the look out for a set of struts in good condition so I can swap the PSF suspension off.
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Old 25-08-2012, 09:17 PM   #1521
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I have a set of vts front struts all standard in good condition?
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Old 25-08-2012, 10:10 PM   #1522
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Dampers, top mounts etc too? Flat bearing hubs?

Thanks also to who ever keeps changing my blog title.
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Old 02-09-2012, 11:41 PM   #1523
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Wow Pete!

I'd love a Caterham but the one I want is about 15k
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Old 03-09-2012, 08:10 AM   #1524
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Wow Pete!

I'd love a Caterham but the one I want is about 15k
It has changed a bit hasn't it? I picked up a Pugsport yesterday and have potentially found an interior so i should have it back on the road soon. Also found someone to unlock my ecu properly so I'll send that off this week.

Which caterham has taken your eye Luigi? A superlight race car would be my ideal car. Sadly they are way out of my budget.
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Old 03-09-2012, 08:58 AM   #1525
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20K for this one with plenty of carbon stuff and many other desirable goodies:



http://www.pistonheads.co.uk/sales/4195187.htm
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Old 17-11-2012, 08:05 PM   #1526
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Tiny update. MOT'd the Rallye at the weekend. 1700 miles since last year and despite all the changes she's still going strong so here are a few pictures. No idea what's up with my iPhone's camera!

New radiator fitted and fan switched from "suck" to "blow".



Standard ecu, ecu tray/cover, loom and air filter. coil pack needs to be swapped back to standard but I havent got round to that yet. I've also fitted the seats from a mk1 VTS but as they're pretty horrid I've not taken any pictures. still quite noisy without carpet and headlining, not to mention the group A engine mounts.





Really loving the car at the moment, I think the return to more manageable levels of power has really brought out the best in the Peugeot Sport suspension set up. Will miss that when it goes.

Lastly a couple of pics of a frosty Rallye.



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Old 17-11-2012, 08:25 PM   #1527
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Why sell the PS set-up?
Enjoy it for what it is!
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Old 17-11-2012, 09:05 PM   #1528
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Would be nice but it's going back to standard. Although if a bargain set of billies came along I'd snap them up.

Next up I need to recon the standard engine and shift the low comp lump. Will also revisit the rust early next year when Simon has the time.
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Old 17-11-2012, 09:20 PM   #1529
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I've got some parcel shelf plastics and fan relay thingy for you! Did S2 Rallyes come with a boot light?
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Old 18-11-2012, 12:01 AM   #1530
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Result. Cheers dude! They did but the wiring for mine is long gone.
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Old 18-11-2012, 09:28 PM   #1531
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Nice work Pete.
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Old 24-11-2012, 12:09 AM   #1532
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Alright pete, been reading up on this little monster!

Shame to see the rotrex go..had you just had enough or are you thinking of escaping the french car game?

Great progress blog none the less
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Old 24-11-2012, 12:36 PM   #1533
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Alright pete, been reading up on this little monster!

Shame to see the rotrex go..had you just had enough or are you thinking of escaping the french car game?

Great progress blog none the less
I miss it too it was a shame to not see it reach it's potential but the choice was chuck loads more money at it or cut my losses. I've had my fun with this car but it's time for something new.

I've still got to swap the engines and sell the low comp lump as hopefully there is a fair chunk of change sat in that.

Replacement wise, I want to build a bike engine kit car.
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Old 24-11-2012, 01:11 PM   #1534
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How are you doing on the list of stuff to get it back near-standard? Did you get seats etc sorted?
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Old 24-11-2012, 04:09 PM   #1535
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Yup, I've got a set of fairly grotty mk1 VTS seats in the car now. Still need door cards, rear quarter plastics, parcel shelf and carpet. Would snap up a Rallye interior if one showed up nearby but they're always in Yorkshire or Somerset

I've got suspension sorted with the exception of front dampers. Engine wise I need to refresh the standard engine (Cambelt, water pump and clutch) and find the time to swap them. Not going to be this side of christmas now.
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Old 24-11-2012, 07:46 PM   #1536
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Hi Pete I've got my s2 door cards an rear plastics in my shed still if your after some?
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Old 24-11-2012, 11:38 PM   #1537
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I've got some front door cards for you but I've just noticed that you've moved area's on the forum, so it'll cost you now! ;-)
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Old 14-07-2013, 10:11 PM   #1538
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Well, Fifi Le Rallye's journey back to standard has taken another big step forward.

Dropped the low comp lump last week and packaged it up ready for a chap called Mark. Hope it gives him many miles of boosted fun.

Also swapped the Group A engine mounts for a near full S2 interior (Cheers Ben!).

Next up, bit of fettling the standard engine before dropping it in. I'm going to do the cam belt, water pump, clutch and input shaft seal.

Current state of play. Paint is looking pretty good I think.

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Old 20-10-2013, 05:40 PM   #1539
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Life has been pretty hectic of late, what with work, exams, a house to decorate and an unhealthy obsession with Lycra.

But, today I finally spent an afternoon on the Rallye. It's MOT time soon so I need to get it back on the road ASAP. Once it's MOTed and the suspension off to a new home it will be up for sale.

Thanks to Aaron I've got a replacement bolt for the cambelt idler pulley (I had to drill the head off the original!) Anyone know what torque setting this should be done up to? Haynes only references the tensioner pulley.

Today i ticked the following off my to do list:

- New water pump fitted
- cambelt idler/tensioner pulleys replaced
- plastics cleaned up
- cam ladders cleaned up and resealed
- camshaft oil seals refitted and pulleys refitted

Hopefully now it's more a case of putting it all back together, timing it up and getting it back in the car.
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Old 20-10-2013, 07:59 PM   #1540
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Coming along nicely mate! Sorry i couldn't help with the bolt, i did have the seals you could of had.

Are you leaving the world of pug's once it's gone then?? I bet you'll be back with a itch one day!

Chris
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Old 21-10-2013, 10:43 PM   #1541
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I'm getting there slowly!

I'd love to keep it but I don't have the space, I've had the car six and a half years and had some great times over the years. Also met loads of people, many I now consider good friends so I will definitely miss the car.

VX220 turbo is the plan, have been out in a couple and loved them but I need to get behind the wheel really and see for myself.
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Old 01-06-2016, 10:39 AM   #1542
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I just read through this in it's entirety. I know it's an old, dead thread now but hat's off to you man.
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Old 01-08-2016, 10:40 AM   #1543
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Quote:
Originally Posted by Aleksandr;
Spent a little more time tinkering this weekend. Finally got round to taking off the J4 inlet and having a look at the throttle cable bracket and mounting the fuel rail. Once again my gigantic injectors cause me problems. The fuel line inlet/outlets are pushed right up against the plenum.

Ive just found a JP4 fuel rail to sort that though. Annoyingly the JP4 fuel rail has a single inlet as the FPR sits above the fuel tank on most later cars. Although I think i've also found an FPR housing from a late model 1.1/VTR/Furio etc which should sort that.



I started mocking up a throttle cable bracket but it might foul the fuel rail so I'll have to put that on hold for the moment.

My J4 plenum broke whilst I was taking it off so if anyone has the top part in good nick I might be looking for one.
how do you put the fuel rail saxo on c2 intake manifolds?
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