406 Turbo Manifold

[pete666 0]

Hi all, just wondering if it was possible to use a 406 turbo manifold on a xu5ja/9 engine? as thinking about building one (attempting anyways lol)

[danpug 1]

Yes. Check out Tom Fentons thread in the project section for some inspiration.

[Moz_Goodwood 0]

i think you can but you will then be stuck with the small turbo that it uses, im sure that someone will confirm this but the "205 parts" manifold will fit and then gives you the option to upgrade, it also helps in clearance issues with the master cylinder

 

i have one for sale aswell if your interested

[sonofsam 5]

Hi all, just wondering if it was possible to use a 406 turbo manifold on a xu5ja/9 engine? as thinking about building one (attempting anyways lol)

 

 

Yes you can. Inevatably you will have to use a Turbo from said 406 as they share the same non standard flange,

so no ordinary T25/GT series turbo will fit that particular manifold unfortunately, but it's not a bad turbo really...

 

 

Brake servo clearence issues will be to do with Turbo housing size and choice!

[wracing 19]

im in the process of doing exactly this, the issues ive had are

 

bulkhead seam clearance

servo clearance

oil return and oil feed have to be made

 

thats it, if you need pics just shout

 

 

james

[Tom Fenton 1,542]

As said above I'm also in the process of this, there is a biggggg thread in the members works section with lots of info and pics, I haven't found any issues with the bulkhead seam, and have got rid of the servo and gone to a twin m/c pedal box for clearance. The gear linkage also needs a slight tweak but nothing too difficult.

Mine is well on the way and should be running very soon hopefully, I've gone for an aftermarket ECU but Henry Yorke has a 1900 converted to turbo and gets away fairly well with the 2.0T management.

[pete666 0]

Hi guys, thanks for all the replies i found toms thread really helpfull (looking really good tom). The only other thing is would the 1.9 be a better engine due to having more torque to begin with? Thanks james i will let you know if need any pics it will be a while till i get started.

 

cheers guys

[danpug 1]

For outright power then the 1.9 will be the better starting point.

[Henry Yorke 269 3 Cars]

Mine is an XU9J1AZ - a Gentry/CTI 1.9 engine which is slightly low compression.

 

Lots of posts on here about poor manifold design and a restrictive turbo etc. Mine goes fine for me running a 2.0 Turbo ECU on a 1.9 engine with different valve sizes, compression, throttle body, cam etc. Granted there will be more in it, but I am happy with 164bhp and 195lb/ft of torque pretty much across the rev range whilst only running 0.5 bar boost and it has worked reliably for over 2 years and has covered a fair few miles. It all depends what you want. There are not many working turbo 205's about as a lot are still ongoing projects aiming for 200+ bhp.

 

The problem you will find is that a lot of the standard second hand turbos are goosed by now and they are not cheap to replace.

 

Not the necessarily most sensible / cost effective build really, but I think Tom and myself have gone down this route more out of curiousity than seeking ultimate power!

[Tom Fenton 1,542]

The problem you will find is that a lot of the standard second hand turbos are goosed by now and they are not cheap to replace.

 

Unless you find a BARGAIN on ebay that is, like I did

[Henry Yorke 269 3 Cars]

Unless you find a BARGAIN on ebay that is, like I did

Yeah yeah yeah.... (8a$t4rD!)

[M@tt 77]

I'd disagree that its not cost effective, you could get a decent £300 quid engine spend another £100 on silicone hoses, an I/C and a bit of fabrication and away you go. You can easily spend £1500 on TB'ing a gti6 and get about 215bhp but wang up the boost on the turbo and you're there for a lot lot less.

 

The wiring is no more difficult than a gti6 i'd say and even thats easy if you can work a wiring diagram.

[wracing 19]

well im all up for the first start of my one tomorrow, see how it goes like i said any info just shout.

 

to give you an idea of cost

 

£150 turbo and manifold

£30 turbo seals and balanced for free

i allready had most of the steel for the pipes but prob about £30 planning to do them in ally soon

£10 oil hoses

custom exaust with one silencer, £20 (its a track slag)

megasquirt injection (£100) already had

£50 25 row oil cooler

£20 cooler hoses

injectors 400cc £50

lamada sensor wideband and controller £50

 

total 510ish

 

thats most of the parts i used minus engine rebuild

 

we will see if it was money well spent tomorrow.

 

imho dont jerryrig the 2.0 turbo injection system im running megasquirt and used the old 8valve loom afm replaced with mat sensor

 

good look all i can say is my conversion has been a learning curve.!

 

wish me luck!

 

james

[danpug 1]

Which engine are you running james?

[wracing 19]

im running a 1.9 the 128bhp one the comp ratio is 9.6:1

 

i don't believe in lowering the compression ratio when theres other means and ways of detonation control.

 

its had a rebuild about 2 track days ago, was looking to get it started today but didn't have time.

 

 

james

[danpug 1]

Look forward to the results!

[Henry Yorke 269 3 Cars]

i don't believe in lowering the compression ratio when theres other means and ways of detonation control.

 

I agree with that. A modern ECU has done away with the need for low CR's on turbos. IIRC the road 205 T16 ran a sub 7:1 CR!!!! It must have been a dog off boost!

[wracing 19]

if im not mistaken the new turbo supercharged vw runs a comp ratio of 11.6:1, it uses direct injection to cool the charge air!

 

richer mixtures, detonation detection, 3d mapping of ignition, better spark technology, charge cooling. are just some of the technologies.

 

if you lower the compression ratio you lose power, why not keep the ratio high and control the other variables better, thats the way forward.

 

7:1 haha at idle must sound like a diesel

 

james