Red 205 Si Restoration Plan

Project Goals

  • Swap the complete XU7 engine and ZF 4HP14 automatic gearbox from a donor Peugeot 306
  • Retain the original Magneti Marelli monopoint G5/G6 EFI system for smooth, reliable running
  • Upgrade front brakes using Peugeot 306 ventilated discs, calipers, and 14" wheels for improved safety and performance
  • Maintain the car as a comfortable and dependable automatic runabout

Two-Stage Work Schedule & Checklist with Time Estimates

Stage One: Donor 306 Strip & Prep

  • [ ] Prepare clean workspace for donor vehicle strip — 1.0 hr
  • [ ] Drain all fluids (engine oil, coolant, transmission fluid) — 0.5 hr
  • [ ] Disconnect wiring, hoses, and label carefully — 2.0 hrs
  • [ ] Remove wheels, brakes, and suspension components, retaining needed parts — 2.0 hrs
  • [ ] Remove complete XU7 engine and ZF 4HP14 transmission assembly — 3.0 hrs
  • [ ] Separate engine and gearbox if needed for refurbishment — 1.0 hr
  • [ ] Transfer 205 monopoint intake manifold and sensors onto XU7 engine — 1.5 hrs
  • [ ] Inspect and refurbish engine components (timing belt, water pump, seals) — 6.0 hrs
  • [ ] Inspect and refurbish transmission (fluid change, filter, seals) — 3.0 hrs
  • [ ] Inspect, clean, and refurbish 306 brake calipers and ventilated discs — 3.0 hrs
  • [ ] Inspect hubs, bearings, and replace brake hoses/adapters as necessary — 2.0 hrs
  • [ ] Organize, label, and store all parts carefully — 1.0 hr
  • [ ] Dispose or recycle non-useful donor parts — 0.5 hr
  • [ ] Order any missing components and tools — 0.5 hr

Stage One Total Estimate: ~26.5 hours

Stage Two: 205 Prep & Swap

  • [ ] Prepare workspace for 205 teardown — 1.0 hr
  • [ ] Drain fluids from 205 (engine oil, coolant, brake fluid) — 0.5 hr
  • [ ] Remove original engine and transmission from 205 — 3.0 hrs
  • [ ] Inspect 205 front hubs and uprights (bearings, seals) — 1.5 hrs
  • [ ] Install prepped donor XU7 engine and ZF 4HP14 transmission using 205 mounts — 4.0 hrs
  • [ ] Connect 205 monopoint wiring loom and ECU to swapped engine — 2.0 hrs
  • [ ] Install 306 ventilated front discs and calipers on 205 hubs — 2.5 hrs
  • [ ] Fit 306 14" wheels with correct tyres for clearance and diameter — 1.0 hr
  • [ ] ✅ Master cylinder already upgraded — no action needed
  • [ ] Fill all fluids and bleed brakes thoroughly — 1.5 hrs
  • [ ] Conduct electrical and mechanical system checks — 1.5 hrs
  • [ ] Perform initial road test and monitor for issues — 1.0 hr
  • [ ] Adjust throttle cable, gear selector, and brakes as needed — 1.5 hrs
  • [ ] Schedule routine post-swap maintenance — 0.5 hr

Stage Two Total Estimate: ~24.5 hours

Scheduling Tips

  • Evenings (Weekdays): Use 1–3 hour windows for draining fluids, cleaning parts, organizing tools, and wiring tasks
  • Weekends: Allocate longer 4–6 hour sessions for engine/trans removal, suspension, brake, and install work
  • Prep Ahead: Order parts and prep tools during the week to maximize weekend productivity
  • Break Up Large Tasks: Spread engine removal or install over multiple sessions if needed
  • Log Progress: Use blog posts to track sessions, issues, or part notes — it keeps momentum going
  • Be Flexible: Build in extra time for stuck bolts, missing tools, or problem-solving

Latest Progress Updates

  • [ ] Add links to blog posts here as you write them

Resources & References

  • Peugeot 205 Si technical manuals and wiring diagrams
  • Recommended parts suppliers
  • Torque specs and service intervals

Last updated: 2025-06-09