[engine_work] Daviewonders Laser Green 205

[Daviewonder 533 3 Cars]

Today was one of those days where I got loads of little bits crossed off my list but nothing spectacular. I fitted the exhaust and lamda sensor, fitted alternator belt, reassembled my instrument panel, removed the oil heat exchanger and fitted a stumpy filter, fitted an adapter and sender to allow me to run the 205 oil pressure gauge, rewired alternator, plumbed in the dump valve, fitted new servo hose and plumbed in the cold start valve.

 

Only thought to take a few pics-

 

 

 

 

Quick tip for removing needles from gauges for those that don't already know it-

 

 

Hopefully get more done tomorrow

[Daviewonder 533 3 Cars]

Today I mounted the cooling fan to the back of the rad. Then I made up the bottom rad mount from the old fan cowling and fitted the rad along with the new top bracket.

 

 

 

 

I also made up some brackets for the intercooler.

 

Thats it for today

Edited April 18, 2010 by Daviewonder

[lloydgti 0]

looks awesome, im running a much smaller intercooler though, same as a cossie 2wd. what gearbox are you using? im using the 1.6 but people have mentioned changing the final drive to the mi16 one. we'll see.

 

cant wait to see what you do next, im getting excited just reading it

[Daviewonder 533 3 Cars]

looks awesome, im running a much smaller intercooler though, same as a cossie 2wd. what gearbox are you using? im using the 1.6 but people have mentioned changing the final drive to the mi16 one. we'll see.

 

cant wait to see what you do next, im getting excited just reading it

 

 

Hi Mate, Cheers.

 

Yeah my intercooler is a little on the large size but i got it for next too nothing and I'll downsize it if it creates too much lag. This is the first turbo engine I've owned so its all going to be a learning curve. My gearbox came with the 205 when I bought it as a rolling shell and is off a 306 2.0 HDI, again I hope this will be ok for the engine but if its not I can always fit a 1.9 one.

 

Good to see you're getting back on with yours

[Daviewonder 533 3 Cars]

Had a spare hour or so today so I nipped down the local scrappy for a look round. As soon as I got there the heavens opened and I was soaked to the bone within a couple of minutes. I was quite surprised by the number of base model 205s that were there (4 or 5) as usually there's only one if you're lucky.

 

Anyway after having a quick check of each I managed to get a perfect condition grille

 

 

Apart for the fact its in the wrong colour its ideal as mine had seen much better days and all the backing was snapped off.

 

 

I also managed to get the missing hose for my cooling system, this one goes from the expansion bottle to the thermostat housing.

 

 

 

And I got the remaining connections for my loom. This should enable me to finish the loom once and for all

 

 

£10 for these bits

 

 

On the way out of the scrapyard something caught my eye so I enquired about the price out of curiosity while I was getting my other bits. 30 seconds latter I was heading back into the scrapyard in a sort of fast walking/skipping/jogging manner with my tools ablazing. 20 minutes later I had myself a set of these-

 

 

Luckily the Guy who works there had only just found time to remove the locking wheel nuts by welding a bolt to them as they didn't have the key. He said they had had lots of interest in them over the past few days but no-one could get them due to not being able to get the wheels off and him not having any spare time. So £50 later I was on my way home with a big grin on my face

[All Praise The GTI 3]

lucky sod!!!

[Daviewonder 533 3 Cars]

lucky sod!!!

 

 

I know I didn't plan on getting brembos for the project but £50 for a set of 4 pots it's got to be worth a go!

 

 

Today after a couple more hours of faffing about I finally came to terms with the fact that I'm not going to be able to fit the evo intercooler without the pipes being squashed against the body and still being able to keep the front grille. So rather than losing the grille I decided to say goodbye to the stupidly oversized intercooler once and for all. Having looked through numerous threads I see that the 2WD Cossie intercooler is quite commonly used in this conversion but I'm not sure if I can use one and keep the radiator at the standard height and keep the grille. I'm now thinking that Sam had a good idea when he used an MR2 intercooler but unfortunately there doesn't seem to be any knocking around at the moment.

 

I also ordered some Baker Bushes and Mountings GRP N top mount rubbers so I can get on with sorting My suspension when these arrive

 

Thats it for today

[Goliath 94]

I've just read through your whole project, it looks very nice, I love laser greens

 

I'm glad you sorted the wiring without too much hassle. I ended up giving up on mine because of the wiring and the difficulty installing the intercooler so i'm glad too see it hasn't beaten you too!

 

Just a note about the red grill you picked up from the scrappy, you can swap the coloured bits over, it can be a bit tricky to separate them but it is possible

 

Good find with the brembo callipers too

 

I will bee keeping an eye on this from now on

[All Praise The GTI 3]

hello mate. its all looking good

just wondering what intercooler that is on page 5?

and is that one or your evo? one up for sale? as i need a cooler to fmic my 306 hdi

Edited May 11, 2010 by All Praise The GTI

[Daviewonder 533 3 Cars]

I've just read through your whole project, it looks very nice, I love laser greens

 

I'm glad you sorted the wiring without too much hassle. I ended up giving up on mine because of the wiring and the difficulty installing the intercooler so i'm glad too see it hasn't beaten you too!

 

Just a note about the red grill you picked up from the scrappy, you can swap the coloured bits over, it can be a bit tricky to separate them but it is possible

 

Good find with the brembo callipers too

 

I will bee keeping an eye on this from now on

 

Cheers Mate, Yeah the wiring wasn't too bad compared to the whole intercooler saga, I struggled for hours with the evo intercooler but I finally admitted defeat (for now ) . Thats a good point about using my green bits on the new backing, I think I'll give it a go. I've seen you are using brembos on your Monster 205, Did you need to use spacers with the Nimrods? Did you use standard 205 hoses onto the caliper pipe? Sorry to hear about your wheels

 

Thanks, Dave

 

 

 

hello mate. its all looking good

just wondering what intercooler that is on page 5?

and is that one or your evo? one up for sale? as i need a cooler to fmic my 306 hdi

 

 

Hi Mate, the intercooler on page 5 is a custom made one that was fitted to a 306 2.0 HDI engine in a 205, Its not a lot of use to me at the moment as the inlet and outlets are too small and I could really do with both of them being at the top of the cooler. I have the pipes that came with it too but I have no use for them either. If your interested Pm me and I'll take some photos for you.

 

Cheers, Dave

[Goliath 94]

Cheers Mate, Yeah the wiring wasn't too bad compared to the whole intercooler saga, I struggled for hours with the evo intercooler but I finally admitted defeat (for now ) . Thats a good point about using my green bits on the new backing, I think I'll give it a go. I've seen you are using brembos on your Monster 205, Did you need to use spacers with the Nimrods? Did you use standard 205 hoses onto the caliper pipe? Sorry to hear about your wheels

 

Thanks, Dave

 

What intercooler are you going to use now? I had an evo 7 one that I was trying to plumb in.

 

My Nimrods are the worse of the 2 offsets so need spacers anyway, I used either 15mm or 20mm spacers (proper hub extensions), I can't remember which though! You need longer flexi hoses to fit the Brembo's, I got mine from Miles for about £30 delivered I think

[Daviewonder 533 3 Cars]

What intercooler are you going to use now? I had an evo 7 one that I was trying to plumb in.

 

My Nimrods are the worse of the 2 offsets so need spacers anyway, I used either 15mm or 20mm spacers (proper hub extensions), I can't remember which though! You need longer flexi hoses to fit the Brembo's, I got mine from Miles for about £30 delivered I think

 

 

I'm trying to find a suitable intercooler at the moment, possibly a 2wd or 4wd cossie one as the others I've looked at had the wrong side pipe diameters, if I have no luck I'll look into getting a custom one made up as there's a local company that does these. Ah the hoses sound ideal, there's some on eBay at the moment for £135.00 but I hope thats a misprint

 

Cheers, Dave

 

 

Quick update, My BBM grp n top mount rubbers arrived today so I should hopefully be able to get my suspension fitted at the weekend, I just need to clean up and paint the hubs

 

Edited May 12, 2010 by Daviewonder

[Daviewonder 533 3 Cars]

Just a very small update. A few months back I was browsing through some old posts from about a year ago on the BX16v forum and I saw a guy had been breaking one for parts, I pm'd the guy on the off chance that he still had the dials and he replied saying he had a few sets and that he wanted a tenner each. He asked my address to work out postage and I replied and asked how he wanted paying. I never heard anything back a few months passed and this morning these arrived-

 

 

These are the ones that have a green back light rather than orange and also have an oil level gauge built into the oil pressure gauge along with ABS light wiring that I hope I can convert to an engine management light.

 

 

The only thing I can think of is that the guys sent them to me to check out before I pay? I've pm'd him to ask how he wants paying and I'm awaiting a reply. But its nice to see there's still good trusting people out there after reading so much lately about scammers.

 

What with the price of these and then the Brembos luck I had I'm hoping good luck comes in threes

Edited May 20, 2010 by Daviewonder

[Goliath 94]

ooh thats nice of him If you fancy selling one of them then let me know as I think my V6 will have a working rev counter using these clocks

[ade 4wd 11]

Those BX clocks have both an ABS lamp and an enginge management lamp.

[marksorrento205 80]

ooh thats nice of him If you fancy selling one of them then let me know as I think my V6 will have a working rev counter using these clocks

 

I dont see why it would not have a working one using the std 205 clocks?

 

Edit: sorry to go off topic, just found it interesting

Edited May 30, 2010 by marksorrento205

[Daviewonder 533 3 Cars]

I dont see why it would not have a working one using the std 205 clocks?

 

Edit: sorry to go off topic, just found it interesting

 

 

I think using one of these is just plug and play, it saves you using all the diodes and stuff that's needed to make a 205 one work properly

 

 

Goliath, I've not quite decided what I'm doing with the spare set of clocks yet but if they go in my 1.9 I'm sure I could do you a deal on the rev counter gubbins as I won't be needing them

[marksorrento205 80]

I think using one of these is just plug and play, it saves you using all the diodes and stuff that's needed to make a 205 one work properly

 

Thats what I was thinking The v6 conversion into a 205 I did was no problem at all to get the std 205 taco working. Just interested to see if it was the reason, and now I know

[jackherer 543]

I'm surprised you can use any 4 cylinder tachos with a 6 cylinder engine without messing around to 'hide' some of the pulses such as connecting to just two out of the three wasted spark coils.

[marksorrento205 80]

Somehow it reads right on idle and also on the limiter. God knows how

 

Edit: Would the fact the wire comes from the ecu not a coil etc?

Edited May 31, 2010 by marksorrento205

[Daviewonder 533 3 Cars]

Somehow it reads right on idle and also on the limiter. God knows how

 

Edit: Would the fact the wire comes from the ecu not a coil etc?

 

Thats what I thought, As we're talking later management doesn't the ecu just get its reading from the TDC sensor and send that to the rev counter?

[welshpug 1,657]

yup

[marksorrento205 80]

There you go then, cheers welshy

[Daviewonder 533 3 Cars]

I believe this only works though if using the rev counter from cars equiped with motronic management and not the earlier jetronic. I'm guessing Goliaths 205 is originally a jetronic model which is why he needs a later rev counter?

[marksorrento205 80]

Not sure, but the car I v6'd was a bog std 205 running on jetronic