1992 Peugeot 106 XSi - Strip, Respray, Rebuild OEM+
Discussion
thiscocks said:
Unless I've missed something I'd personally just stick with the oe iron block xsi engine- atleast you know what you've got then. Hopefully the bores will be good then you can just get some new rings maybe do the crank bearings ect and maybe polish the head up and get new valve seals ect and it should go a treat! I spent loads on my old Rallye S1 engine on custom management ect but although it was good when it worked, the oem spec engine was just as nice in use and probably better on the road.
The engine in the car is an ally block (probably 306 75hp spec), so the difficulty is lifting/dropping it and getting it out of there. The 'spare' iron block isn't original to that car, but another of unknown provenance. Supposedly rebuilt but when I pull the head, we shall see. Let's face it - I have not had the best of luck with these engines. If I rebuild one from scratch (which is fine) then I'll get a crane in. The iron block is bloody heavy though. Can pick an aluminium engine up and put it on the bench myself... An iron block - no way! I can remember picking up a Pinto boat anchor when I built my first engine at 18... I was in better shape 23yrs ago!
The more I write, the more I think going back to the iron block is the way forward, except I am missing some of the ancillary bits like the block->rad connection. I'd probably still want another iron block engine (even a £150 FB marketplace special) to make sure I have all the bits. It's worth it to me. The XSi engine I thought I would get from eBay, but lost out on, was only £200 including the ancillaries and loom
OEM is best but I did like the idea of a lighter nose i.e. ally block. But Dave Baker (the guru of us Peugeot fiends, in my 205 days, 15yrs ago) did tell me to stick with the iron block. I didn't ignore him, per se, but when the car came with an ally block... it was just a lot less work. Or looked it.
Custom management would be cool, as things have more than moved on in almost 30yrs but I'll make sure the engine is solid engine first!
If I go iron block... I fancy going 1.6 for the torque bump. Would make me feel better for the weight penalty. There is a 23k motor on Facebook Marketplace
This thread is not a great advert for the venerable old tu is it!
Yea go full fat Dom 1600 and then some.......... good value engines come up from time to time. I was talking with this guy at one point, he wanted 2k originally with bodies and management I was going to buy it As a spare but it got snapped up https://www.ebay.co.uk/itm/Saxo-8v-Race-engine-For...
If you do get a 1.6 (black top) drop me a PM as I have my old very well set up bike carb setup including inlet, cam, itg filter/backplate coilpacks/brackets and everything needed to get fitted and running doing nothing here that you can have for postage - it made 132 smoothly on a standard (albeit heavily skimmed) head and certainly would be a period mod!
Yea go full fat Dom 1600 and then some.......... good value engines come up from time to time. I was talking with this guy at one point, he wanted 2k originally with bodies and management I was going to buy it As a spare but it got snapped up https://www.ebay.co.uk/itm/Saxo-8v-Race-engine-For...
If you do get a 1.6 (black top) drop me a PM as I have my old very well set up bike carb setup including inlet, cam, itg filter/backplate coilpacks/brackets and everything needed to get fitted and running doing nothing here that you can have for postage - it made 132 smoothly on a standard (albeit heavily skimmed) head and certainly would be a period mod!
To be fair... probably a worse advert for my skills! 
I never saw that engine! I don't use saxo search terms! Looks like a good deal. I'd think getting a pro to put one back together with my best parts and new rings, bearings, machining, gaskets, etc would cost that!
I don't want to think about it but I'm probably not far off that in 'wasted' parts... gulp!
It'll get there. Let's see what Engine 3 has hidden. My luck is due to turn and I did rather throw that last head on... if in doubt; build the engine in its entirety yourself on the bench and then you know it's good.
The more I think about it... the more I fancy a TU5 8v block... or is that giving up too soon?
Always wanted some bike carbs. Bought some blackbird carbs back in 2004 or something. Think they even came to America with me when I moved there... Think they disappeared in a house move way back when!
I never saw that engine! I don't use saxo search terms! Looks like a good deal. I'd think getting a pro to put one back together with my best parts and new rings, bearings, machining, gaskets, etc would cost that!
I don't want to think about it but I'm probably not far off that in 'wasted' parts... gulp!
It'll get there. Let's see what Engine 3 has hidden. My luck is due to turn and I did rather throw that last head on... if in doubt; build the engine in its entirety yourself on the bench and then you know it's good.
The more I think about it... the more I fancy a TU5 8v block... or is that giving up too soon?
Always wanted some bike carbs. Bought some blackbird carbs back in 2004 or something. Think they even came to America with me when I moved there... Think they disappeared in a house move way back when!
Brilliant thread,
The engine about with the ITB's was out of my old race car i raced in stock hatch in 2009-10 but owner had changed a lot of the spec by then.
I am racing again in the 106 Xsi this year if the season ever gets back, and love following this build. to get the proven best power out of the Tu5 you need
saxo mk3 Bottom end with the raised pistons and short skirt along with a mk1 early saxo , s1 or s2 , xsi head and J Cam from the rallye, a good aftermarket ecu and exhaust will see easy 130-135bhp with a s1 inlet.
can i ask if you haven many spares from the xsi, im after a induction pipework that goes to the airbox?
The engine about with the ITB's was out of my old race car i raced in stock hatch in 2009-10 but owner had changed a lot of the spec by then.
I am racing again in the 106 Xsi this year if the season ever gets back, and love following this build. to get the proven best power out of the Tu5 you need
saxo mk3 Bottom end with the raised pistons and short skirt along with a mk1 early saxo , s1 or s2 , xsi head and J Cam from the rallye, a good aftermarket ecu and exhaust will see easy 130-135bhp with a s1 inlet.
can i ask if you haven many spares from the xsi, im after a induction pipework that goes to the airbox?
roosie said:
Brilliant thread,
The engine about with the ITB's was out of my old race car i raced in stock hatch in 2009-10 but owner had changed a lot of the spec by then.
I am racing again in the 106 Xsi this year if the season ever gets back, and love following this build. to get the proven best power out of the Tu5 you need
saxo mk3 Bottom end with the raised pistons and short skirt along with a mk1 early saxo , s1 or s2 , xsi head and J Cam from the rallye, a good aftermarket ecu and exhaust will see easy 130-135bhp with a s1 inlet.
can i ask if you haven many spares from the xsi, im after a induction pipework that goes to the airbox?
Thanks for the nice comment... but I suspect this could have gone smoother and been more inspiring!The engine about with the ITB's was out of my old race car i raced in stock hatch in 2009-10 but owner had changed a lot of the spec by then.
I am racing again in the 106 Xsi this year if the season ever gets back, and love following this build. to get the proven best power out of the Tu5 you need
saxo mk3 Bottom end with the raised pistons and short skirt along with a mk1 early saxo , s1 or s2 , xsi head and J Cam from the rallye, a good aftermarket ecu and exhaust will see easy 130-135bhp with a s1 inlet.
can i ask if you haven many spares from the xsi, im after a induction pipework that goes to the airbox?
Ah ha - You're the guy who is asking on Facebook, when I do my XSi parts search
I do think I have that pipe and almost messaged you on there... but I don't know if I am going to use it yet, so didn't want to speak too soon.
Induction was to come after the engine was running and although I am sticking with the standard airbox; I do have one of those closed, fake carbon induction kits I was considering piping up (without the weird, little filter, hence keeping the standard box). The connection to the airbox though is annoyingly oval. If I can find a suitable 'link' solution - it's yours. But, like I say; it could be a while!
If you have a Saxo Mk.3 bottom end - swap?
All jokes aside - assume that is a late Saxo VTR then? Do you have a model year or, better yet, point me to a link for what I might want?
I still think it would be a bit of a waste not building an engine from what I have as, if nothing needs a lot of machining, it would be cheap and clears the garage of engines!
2 x XSi heads, 2 x J (or Z, need to check) cams, 1 x Piper cam, 2 x ally blocks, 1 x iron block, all manner of engine mounts, alternators, brackets, etc, etc. An XSi gearbox, a 1.1 gearbox (in the car), blah, blah, blah. If no (or minimal) machining was required; I'm a couple of sets of bearings and piston rings from two full engines.
dom9 said:
thiscocks said:
Unless I've missed something I'd personally just stick with the oe iron block xsi engine- atleast you know what you've got then. Hopefully the bores will be good then you can just get some new rings maybe do the crank bearings ect and maybe polish the head up and get new valve seals ect and it should go a treat! I spent loads on my old Rallye S1 engine on custom management ect but although it was good when it worked, the oem spec engine was just as nice in use and probably better on the road.
The engine in the car is an ally block (probably 306 75hp spec), so the difficulty is lifting/dropping it and getting it out of there. The 'spare' iron block isn't original to that car, but another of unknown provenance. Supposedly rebuilt but when I pull the head, we shall see. Let's face it - I have not had the best of luck with these engines. If I rebuild one from scratch (which is fine) then I'll get a crane in. The iron block is bloody heavy though. Can pick an aluminium engine up and put it on the bench myself... An iron block - no way! I can remember picking up a Pinto boat anchor when I built my first engine at 18... I was in better shape 23yrs ago!
The more I write, the more I think going back to the iron block is the way forward, except I am missing some of the ancillary bits like the block->rad connection. I'd probably still want another iron block engine (even a £150 FB marketplace special) to make sure I have all the bits. It's worth it to me. The XSi engine I thought I would get from eBay, but lost out on, was only £200 including the ancillaries and loom
OEM is best but I did like the idea of a lighter nose i.e. ally block. But Dave Baker (the guru of us Peugeot fiends, in my 205 days, 15yrs ago) did tell me to stick with the iron block. I didn't ignore him, per se, but when the car came with an ally block... it was just a lot less work. Or looked it.
Custom management would be cool, as things have more than moved on in almost 30yrs but I'll make sure the engine is solid engine first!
If I go iron block... I fancy going 1.6 for the torque bump. Would make me feel better for the weight penalty. There is a 23k motor on Facebook Marketplace
Awesome car you have there mate, I love a 106 I had a blaze yellow GTI years ago. It was fantastic when it wasn’t spitting bits of gearbox through the casing. I think it had about 6 boxes in about a year the last box I put in on my own and was surprised when I went for 5th and it didnt have one!
Spent 3 hours reading all this from the beginning and feel emotianally drained so massive respect to you for sticking with it 
I was in a similar frame of mind to you after having a 205 gti back in my youth but I ended up with a phase 2 Clio 172 which is i'm loving.
Anyhoo, you inspired me to get my Alfa 156 V6 'fast shed spec' finished as it's been sat since before lockdown awaiting brakes and obscure electrical components.
Hope you get the car to where you want it and i'll be cheering you onwards!
I was in a similar frame of mind to you after having a 205 gti back in my youth but I ended up with a phase 2 Clio 172 which is i'm loving.
Anyhoo, you inspired me to get my Alfa 156 V6 'fast shed spec' finished as it's been sat since before lockdown awaiting brakes and obscure electrical components.
Hope you get the car to where you want it and i'll be cheering you onwards!
Sorry chaps (and/or chapesses)... not ignoring you!
6hrs straight on a call between Milan and Venezuela and writing a document until now... the car and PH has not been at the forefront of my mind!
It looks like it'll be the weekend before the next progress is made. With the weather turning, that may be pulling the head off the iron block in the garage, before I attack the car with the ratchet again!
I am glad to inspire;p, but if (mostly when in my case) it all goes wrong... I wasn't here, right!
6hrs straight on a call between Milan and Venezuela and writing a document until now... the car and PH has not been at the forefront of my mind!
It looks like it'll be the weekend before the next progress is made. With the weather turning, that may be pulling the head off the iron block in the garage, before I attack the car with the ratchet again!
I am glad to inspire;p, but if (mostly when in my case) it all goes wrong... I wasn't here, right!
Virtual beer whizzing through the internet
I thought it would be in far worse condition than it is. It's in far better condition than mine started off in and has a lot of 'better' parts that I'd have never bothered looking for but will swap over e.g. some windows trim etc.
It's a shame I won't need a lot of it, to be honest. Using the odd thing here and there will basically kill it. I haven't got time to break it for others so hopefully I can pass on what's left to someone else who needs parts.
What a cracking guy selling it as well. Top man.
I thought it would be in far worse condition than it is. It's in far better condition than mine started off in and has a lot of 'better' parts that I'd have never bothered looking for but will swap over e.g. some windows trim etc.
It's a shame I won't need a lot of it, to be honest. Using the odd thing here and there will basically kill it. I haven't got time to break it for others so hopefully I can pass on what's left to someone else who needs parts.
What a cracking guy selling it as well. Top man.
Surprise or not, as it turns out
What a great guy the seller was. Think the deal was a good one, to the point I'd feel a bit bad about selling spares on.
Work is still mad busy so maybe no chance to have a play until next weekend but it drove into position, which is more than can be said of car No.1!
Will get some pics of the new one (on the right, hopefully obvious) and dig through it all. Will have a lot of spares!
I think an engine bay switch straight over and rebuild a new engine while the original one is on the road with the 'new car' engine and 'box is priority 1.
So, very, very close to getting it back on the road, I guess, if the time/extra hands required to do the swap are available.
'New one' has some fancy bits like coilover converted struts will new Billies in them. But I have new Billy cartridges so need to think about what to swap over/sell/scrap.
The rear beam is lowered, tyres are Yoko A048Rs (so nice and sticky), the door/window rubbers and seals are better, obviously all the looms, etc, etc.
I have more seats (remember I had a spare set) than I know what to do with and things like front wings. A spare set of wings and arch trims might be nice to keep as they're hard to get but a lot could go. I'd struggle with the time to break and sell things though.
I should probably run a 106 XSi charity - bring your own spanners and take what you need
Clio V6 is now underground at my best mates house as he has one of those disappearing car lifts on his drive - fancy!
What a great guy the seller was. Think the deal was a good one, to the point I'd feel a bit bad about selling spares on.
Work is still mad busy so maybe no chance to have a play until next weekend but it drove into position, which is more than can be said of car No.1!
Will get some pics of the new one (on the right, hopefully obvious) and dig through it all. Will have a lot of spares!
I think an engine bay switch straight over and rebuild a new engine while the original one is on the road with the 'new car' engine and 'box is priority 1.
So, very, very close to getting it back on the road, I guess, if the time/extra hands required to do the swap are available.
'New one' has some fancy bits like coilover converted struts will new Billies in them. But I have new Billy cartridges so need to think about what to swap over/sell/scrap.
The rear beam is lowered, tyres are Yoko A048Rs (so nice and sticky), the door/window rubbers and seals are better, obviously all the looms, etc, etc.
I have more seats (remember I had a spare set) than I know what to do with and things like front wings. A spare set of wings and arch trims might be nice to keep as they're hard to get but a lot could go. I'd struggle with the time to break and sell things though.
I should probably run a 106 XSi charity - bring your own spanners and take what you need
Clio V6 is now underground at my best mates house as he has one of those disappearing car lifts on his drive - fancy!
Nice...... Sorry ruined your suprise.... it did look like good value - I had seen the xsi and thought about it for about a second before rembering that I was looking for something different and more family inclusive than a 106 despite the fact I have a LOT of parts and access to a 35k clean s1 shell to make another one up as a white XSI if I had got the eBay one as well.
Instead I shall keep searching for a Renault 21 turbo or Citroen BX GTi....
At least it will save a lot of hassle with sourcing parts...... I am after a headlight loom too if you have one???
Regarding the a048s... Check the dates as they don't keep well and too many winters outdoors won't help.
I run them on my S2 as summer tyres and they are excellent with the right suspension bits
Pic
Instead I shall keep searching for a Renault 21 turbo or Citroen BX GTi....
At least it will save a lot of hassle with sourcing parts...... I am after a headlight loom too if you have one???
Regarding the a048s... Check the dates as they don't keep well and too many winters outdoors won't help.
I run them on my S2 as summer tyres and they are excellent with the right suspension bits
Pic
ICallCustard said:
I was considering that car! Glad it will help you finish your project though
Thanks bud - I think I needed it to spur me on! It basically guarantees completion this summer... he says!I got a very good deal indeed, commensurate with my original car purchase but with the right engine and 'box and some fancy parts, albeit some rust and missing interior bits, etc.
So, I'll stop taking engines apart for a while and get the car 'finished' and on the road, then get back to them.
I have been having some bad thoughts though... https://www.205gtidrivers.com/forums/topic/67197-1...
TU3 alloy block + TU5 crank + XSi head + skimmed XSi pistons + piper cam = torquey fun? I have all the parts (for probably 2)... except a £50 crank off eBay.
shedweller said:
Nice...... Sorry ruined your suprise.... it did look like good value - I had seen the xsi and thought about it for about a second before rembering that I was looking for something different and more family inclusive than a 106 despite the fact I have a LOT of parts and access to a 35k clean s1 shell to make another one up as a white XSI if I had got the eBay one as well.
Instead I shall keep searching for a Renault 21 turbo or Citroen BX GTi....
At least it will save a lot of hassle with sourcing parts...... I am after a headlight loom too if you have one???
Regarding the a048s... Check the dates as they don't keep well and too many winters outdoors won't help.
I run them on my S2 as summer tyres and they are excellent with the right suspension bits
No surprise ruined Instead I shall keep searching for a Renault 21 turbo or Citroen BX GTi....
At least it will save a lot of hassle with sourcing parts...... I am after a headlight loom too if you have one???
Regarding the a048s... Check the dates as they don't keep well and too many winters outdoors won't help.
I run them on my S2 as summer tyres and they are excellent with the right suspension bits
All this spare engine chat does have me wondering about a super clean, base spec S1 transplant.
Something like this, I may have posted before (or maybe that was on the transplant thread):
I will have the headlight loom that comes off the original car. It might be ok but it does look somewhat hacked about. We can have a look when it's off.
Good point on the A048s! I remember them being very expensive when I was looking at trackday tyres for my 996 in 18"s so went with Toyo 888s.
I am new to this forum and found your post of which I read with interest. I too own a Peugeot 106 XSI and reading your posts made me think about my own and the work I have done on it over the years. Unfortunately mine has sat dormant in the garage for the last 10 years and to give me something to do during the covid crisis I decided to restore and get her back on the road. I didn't think that there would be many of these cars still around so it was interesting to learn there are others.
Hoping to have her on the road soon. Still a few jobs to do but it's taking shape nicely.
Hoping to have her on the road soon. Still a few jobs to do but it's taking shape nicely.
That's great news! Get some pics up here - it'll inspire me! Two did not become one, yet. My help let me down and I didn't fancy a solo effort with the weather being so changeable at the moment.
Away for 4 days from tomorrow so this weekend is a bust but it looks like summer may be returning after that.
Joined Instagram as there still seem to be a fair few on the road, if you follow the hashtags.
Away for 4 days from tomorrow so this weekend is a bust but it looks like summer may be returning after that.
Joined Instagram as there still seem to be a fair few on the road, if you follow the hashtags.
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