[engine_work] 205 Gti6 Conversion

[Retro Pug 0 1 Cars]

Well after having a GTI6 engine in the garage for the last 18 months I thought it was time to at least introduce it to the car...

All is going quite well 1.6 is out and we've had a few trial fits looks like the master cylinder clearance is going to be the biggest issue....

 

The other thing that is bothering me is the aux belt tensioner. I'm not using the power steering and I'm sure I've seen a picture of someone using the 205 GTI alternator? Can anyone point me in the right direction?

 

This is our first conversion, wish us luck!!

 

Below are the pics so far....

 

The car..

 

1.6

 

0.0

 

2.0

[gti-si 0]

Good progress there.

 

There are quite a few different ways of combatting the alternator, if you have a search through threads in the works section you'll be sure to find plenty of info. You can use either the 8v or 16v alterator, it depends how you want to tension it. A simple way is to modify the original 8v tensioner slightly and use that with a good size belt. There's no definitive answer though, you just have to see what works.

 

Good luck with the conversion

[chrisj21 2]

Nice progress.

 

It looks like your starting with a very nice car too.

 

I think edp has some good pictures of what he did to his tensioner in his project thread.

[Retro Pug 0 1 Cars]

Thanks for comments.

 

Yes not bad progress so far I hope to have all the mechanical work done this week so then it will be the electrical problems to worry about.... I've posted in the wanted section for a dual vehicle speed sensor - did not realise I needed that!

[Retro Pug 0 1 Cars]

Well engine is now bolted in and without too many clearance issues. The master cylinder was the biggest problem, but should be fine after a little work.

 

The down pipe needs sorting and I'm yet to sort out my alternator issues but all is moving along quite nicely!

[Retro Pug 0 1 Cars]

I'm hoping to get a lot more done this week.

 

I have a few questions I'm hoping someone can help with.

 

I've tried to search on cooling and I'm sure I've seen some diagrams somewhere... Anyway can someone help me understand how the setup works? I have a samco GTI6 kit and all the 8v hoses do I need anything else?

 

Can anyone suggest a cone type filter to fit on the throttle body? What size do I need?

 

Apologies I'm sure these seem simple to most..

Thanks

John

[Paul_13 212 1 Cars]

Have a little gander on my build thread or Spiky's as I've been pestering him about his conversion and how to do mine lol

[2052006 10]

I've plumbed mine in as near to the 8v setup as possible. Used a new water dist block on the back - part number on Platty's build thead iirc - and had to extend the block-matrix hose and block-expansion tank hose slightly to properly clear the '6 manifold. Used a BBM adapter on the thermostat housing to enable use of the original 8v top rad hose. And done away with the '6 heat exchanger gubbins. Basically used all the original 8v hoses.

 

Although I haven't driven it yet, I have run it up to temperature a few times and it seems to be fine.

 

Oh, and I believe you need a 76mm neck for a filter if fitting straight on to the T/B.

Edited July 6, 2009 by 2052006

[Retro Pug 0 1 Cars]

Thanks for the replies, really helpfull.

[Retro Pug 0 1 Cars]

Can anyone tell me which throttle cable I need. Am I right to think I need a longer one?

[gti-si 0]

Yeah you do need a longer one. Just by a cable kit, can get them from ECP/GSF. You just cut it to length and then add the nib on the end, tighten it up at the correct length and job done

[Retro Pug 0 1 Cars]

Yeah you do need a longer one. Just by a cable kit, can get them from ECP/GSF. You just cut it to length and then add the nib on the end, tighten it up at the correct length and job done

 

Thanks mate.

 

Managed to get a bit more done tonight, but spent a lot of time thinking and measuring! I've got one of the Rad-Tec radiators which is pretty wide, so oil filter clearance with the oil cooler sandwich plate looks like a bit of an issue. Hopefully we'll sort soon, really starting to miss driving it now

[Paul_13 212 1 Cars]

Here's a page from Spiky's build on how he plumbed up the coolant.

 

Coolant diagram

 

You'll probably want to miss out the oil cooler bit

[Retro Pug 0 1 Cars]

Thanks mate, really helpful.

[Retro Pug 0 1 Cars]

Ok quick update time and a question....

 

Majority of work I'd say is done, the exhaust downpipe has been shortened, lambda probe is boted on and all is refitted. Most of the plumbing is now done just need to properly mount the rad and oil cooler. I have the Rad-Tec radiator from the group buy organised by 'Daz C' a while back and a 13 row Mocal cooler I picked up qiute cheaply.

 

Most of the loom is on thanks to Taylorspug's advice and help! I'm hoping to get it running this week - work and family commitments allowing.

 

Now the question - can anyone find me the part number for the VSS I'm really stuggling to find it! (It's the s-16 dual input type) If I can get the part number I might be able to get a few motor factors to do a bit of digging, the only one they've come up with so far is the GTI6....

 

Cheers all.

Edited July 17, 2009 by Retro Pug

[welshpug 1,657]

1.4/1.6 phase 1 306, plenty of them in scrappies

Edited July 17, 2009 by welshpug

[Retro Pug 0 1 Cars]

Spent a bit more time on the car tonight and got most things wired up and ready for a test start. After a lot of the engine just turning over it grumbled into life and then died. It did this a few times and on our last attempt it idled for a few seconds before it died again.

 

Any attempt to open the throttle results in the engine cutting out. I'm thinking some sort of fueling problem but can't think what is causing it? Anyone have any ideas?

 

Would be nice to get this back on the road now......

[gti-si 0]

Got enough fuel in the tank?

 

Does sound like a fueling issue however.

[Retro Pug 0 1 Cars]

Got enough fuel in the tank?

 

Does sound like a fueling issue however.

 

 

Yeah plenty of fuel in the tank but refuses run properly, I'm hoping its fueling. I guess its a big question but could it be anything else?

[gti-si 0]

You've got rid of the inertia switch haven't you?

 

Firstly check all your sensors are on the right plugs around the TB. Most importantly, map sensor and TPS. Then check you've got the cam sensor on proerply and a good connection on the crank sensor.

 

Failing that I'd take the injectors out, get them spraying into a jar, you can then check you actually have fuel and check the spray pattern for any problems there. At least if something isn't right with the fueling you'll find out then. If not then you can rule it out. Then whip out a plug and check for a consistant spark

 

That lot should give you something towards finding your fault

Edited July 23, 2009 by gti-si

[Paul_13 212 1 Cars]

Blocked fuel filter maybe?

Cr@p earth?

[Retro Pug 0 1 Cars]

After a bit of a holiday I got back to the garage and had another look at the car checked the fuel lines and fitted a new earth and then fitted the plugs on the MAP and TPS in the right order!!! Engine then started up no probelms.

 

Hopefully will get some more time on the car soon to get the Rad, oil cooler and ECU mounted properly and all should be well!

[gti-si 0]

Glad to hear

[marksorrento205 80]

Good effort! Car looks a goodun to start with too. Got anymore pics of the engine progress and the car its self?

[Fox 3]

Good going, you need more photos though!

 

The speedo sensor is the same as a 106 rallye too, a quick post on the rallyeforum wanted section may help...

 

I managed to pinch one of a mate, they seem to be a bit of a rare part to find in the scrappys