[car_overhaul] Nickaliath's 205 GTI Overhaul

[nickaliath 22]

ok ill check that out tonight and post up the others ive done.

[nickaliath 22]

It should have been yellow 410 oil pressure warning light. i wrote it wrong.

 

So heres the list again with additional wiring added.

 

GTI-6 19pin round plug - 205 brown multiplug

 

Beige 401 coolant temp sender - Red 47a coolant gauge

Yellow 410 oil pressure warning light - Purple 30 oil pressure light

Red 411 oil temp sender - White 30a oil temp gauge

Grey c120 reverse light switch - Dark grey 52 reverse light

Orange 220 reverse light switch - Purple 53 reverse light

Dark brown 1070 alternator warning - Dark grey 7a alternator light

Thick White 120 Fuel pump - White 76 fuel pump

white 400 coolant temp gauge sender - yellow 47 coolant light

 

Grey CC1 air bag control unit?? Switched +live - Red 2a switched live

Red 426 obd + rev counter - Grey 112b tacho feed

Thick White 100 switched +live to starter - Blue 46b starter

 

 

Ive got this connection below also which i think is wrong, but just noticed!!!

yellow 414 oil level gauge - grey 30b oil pressure gauge

 

 

ive got two wires that i havent connected yet from the 205 gti loom these are:

 

- Green/yellow M ignition amp

- Yellow 32a tachy relay

 

ive also got seven wire unconnected from the 19pin gti-6 loom these are (the bold ones im guessing arent to be used:

 

- Green 140 obd socket

- beige 121 obd socket

- beige 480 engine fault light

- yellow/green m444 permenant earth

- green 415 oil level gauge

- yellow 465 vehicle speed sensor

- grey 123 switched +live powers lambda sensor

 

 

Any advice would be much appreciated.

[nickaliath 22]

any ideas?

[OlberJ 1]

Excellent thread, for a couple of reasons.

 

No.1 that Cossie Evo is outstanding. I know everyone does it, and it's a cliche but i'd be tempted to put the AMG wheels on that. Even so, it's bloody class.

 

No.2 your FI GTi-6. Are you planning to uprate the internals or will this be a low boost turbo? Which turbo you thinking of using? How are you planning to control it?

 

 

And is this on the 1.9 box i take it?

[nickaliath 22]

I did have brabus wheels on it originally but decided to go original.

 

well im just concerned with getting it running right to begin with standard. in the future i will plan the turbo conversion. probably go witha t28.

 

1.9 gearbox using mi16 clutch

[nickaliath 22]

If anyone could cast there eye over the wiring it would be much appreciated.

 

I managed to get most of the dash back together today leaving only a part from under the steering column so i can put in the engine loom.

[Galifrey 1]

Can't really help as Miles did mine, have you read THIS thread?

[nickaliath 22]

thats based on a citroen loom which seems to be slightly different

[Miles 331 1 Cars]

Easy way to start, Is remove all the items you don;t need and check on the Autodata Wiring Diag which may or maynot be on this site, Then find the switched live and the switched live for the Lambda, Live for the loom which is normally on the Alt and thats it

[nickaliath 22]

Right i think i understand you?!!

 

So i think what ive done already is basically ok. but i need to put the other switched live from the lambda spliced into the switched live already connected. Im presuming the live for the loom is already on there in the form of a ring connection which connects to the alternator?

[nickaliath 22]

right this is how i have done all the wiring hopefully it will work all ok.

 

Beige 401 coolant temp sender - Red 47a coolant gauge

Yellow 410 oil pressure warning light - Purple 30 oil pressure light

Red 411 oil temp sender - White 30a oil temp gauge

Grey c120 reverse light switch - Dark grey 52 reverse light

Orange 220 reverse light switch - Purple 53 reverse light

Dark brown 1070 alternator warning - Dark grey 7a alternator light

Thick White 120 Fuel pump - White 76 fuel pump

white 400 coolant temp gauge sender - yellow 47 coolant light

Grey CC1 air bag control unit?? Switched +live - Red 2a switched live

Red 426 obd + rev counter - Grey 112b tacho feed

Thick White 100 switched +live to starter & grey 123 switched +live powers lambda sensor - Blue 46b starter

yellow 414 oil level gauge Rewired to 205 oil pressure sender) - grey 30b oil pressure gauge

yellow/green m444 permenant earth - Green/yellow M ignition amp

 

left from 205 loom

- Yellow 32a tachy relay

 

left unused from gti6 loom

 

- Green 140 obd socket

- beige 121 obd socket

- beige 480 engine fault light

- green 415 oil level gauge

- yellow 465 vehicle speed sensor

[nickaliath 22]

Managed to get my engine all mounted up today. Got the new mi16 clutch fitted along with my new top engine mounting.

 

Didnt prove to be too much trouble, although the brake master cylinder is hitting the top of the engine and removed exhaust manifold as needs to be modified.

 

Fitted my 8V auxiliary belt from crank pulley to alternator pulley, all i did was to space out the top mounitng on the alternator and bolt it up behind it. (pictures to follow, hopefully it wont be too tight.

 

 

Found a connection on my loom that am usure where it goes?? i think it might be off a part on the gti-6 but any help to what it is would be appreciated.

 

 

Got my seats fitted in the week although i want to tidy them up a bit more, maybe buy a kit to supple them up and bring back the colour in them?!

 

 

 

 

On a whole at the moment it all looks a bit tatty, but as soon as i have it all running then the tidying will start.

Edited December 12, 2009 by nickaliath

[Alastairh 47]

Found a connection on my loom that am usure where it goes?? i think it might be off a part on the gti-6 but any help to what it is would be appreciated.

 

Lamba sensor?

[nickaliath 22]

didnt think of that!! i will check with my multimeter tomorow. thanks

[nickaliath 22]

here is how i mounted my 8v aux belt putting a bolt through behind the normal mounitng hole on the top of the alternator.

 

[nickaliath 22]

Today i have cut my exhaust manifold for re-angling to clear bulkhead.

 

Went to try it in for a test fit before welding but cannot fit it in from the engine bay!!!! has anyone else had problems fitting an exhaust manifold on the gti-6 engine whilst its in the car?

 

I think i shall attempt to fit it from underneath the vehicle on the weekend.

[nickaliath 22]

4 zs

[nickaliath 22]

dont know what that was about?

 

I have fitted the inlet manifold on today.

 

i also connected up some electrics.

 

there are some bits that im not sutre if are needed or what they do??

 

dont now what this does or where it goes.

someone said that this hose from the brake servo connects to this part on the engine? is it true?

not sure where this connector goes?

Edited December 18, 2009 by nickaliath

[SurGie 54]

The first pic is the charcoal canister not needed for the conversion.

 

I am finding this project thread a good one with lots of good questions and info.

 

(my one thousandth post ) not that it matters.

Edited December 21, 2009 by SurGie

[Galifrey 1]

 

Is the vacuum pump and can be connected to the brake servo

[ben_kilpatrick205 0]

There is also anthother take off for this on the inlet manifold but you can blank that one off if you use the vacuum pump

 

Let me know if you get the exhaust manifold in with the engine in because i dont think i could?

[Galifrey 1]

There is also anthother take off for this on the inlet manifold but you can blank that one off if you use the vacuum pump

 

Correct, I think Miles said as standard it's Teed onto the vacuum pump, but not needed.

 

Can see mine with a small length of blue silicon and a plug here

 

[lukegroves_123 0]

Hi really informative post, very handy as i'm in the middle of a gti6 conversion myself. how much/what angle did you cut the exhaust manifold to fit? thanks

[nickaliath 22]

thanks for all the great replies.

 

Im trying to ask as many questions and add as much info as possible throughout this conversion to help others. It would be better if they could follow this complete progress instead of sifting through various projects to find answers.

 

I will post a pic up with the cut angle when its in the right place.

[2052006 10]

Correct, I think Miles said as standard it's Teed onto the vacuum pump, but not needed.

 

Can see mine with a small length of blue silicon and a plug here

 

 

 

Is there any benefit to removing this pipe between manifold and vacuum pump? I still have it fitted on mine for what it's worth.