[car_upgrade] My 205 8vt Project

[Jamal 2]

Hi!

 

I've started my conversation on february 2009. I will tell the story retroactively, because my work is almost done but I want to share this with You.

 

The engine came from a damaged 95/96 Citroen Xantia. The engine loom was damaged, I wasn't able to start the engine, but after going under the car and seen the rebuilt turbo I decided to buy it.

 

It's important to tell, that this engine is not a common and affordable one in Hungary.

 

Some pics from the start

 

The car(Yes it's a huge GMC trailer ):

The damaged engine bay:

 

 

Some pics about the engine:

[Galifrey 1]

Nice start, did the Citroen owner store his car in a riverbed?

 

Might want to edit the pic size to 800x600 to keep the mods off your back

[Jamal 2]

Nice start, did the Citroen owner store his car in a riverbed?

 

Might want to edit the pic size to 800x600 to keep the mods off your back

 

The car were sleeping for 2 years on a "farm" in a little village near my town.

 

Sorry for the pics, the next post will be OK.

[Jamal 2]

After the disassamble I decided to take it to a local engine refurbisher to change the rings, machine the crankshaft and change the bearings.

 

They wanted to trick me, said that the engine is needed to drill. But there was one problem, the honing was very deep and beautiful(as You can see on the pics)

 

After the engine shop:

 

To see, how terrible was the condition of the engine:

 

Slowly I cleaned the parts with nitro dilution:

[omega 82]

wow love that transporter

[Jamal 2]

While the block was at the machine shop i brougth the head to a specialist.

They skimmed, ported and regrinded the valves, changed the valve guides and the valve stem seals.

 

The turbo:

 

Starting to rebuild the engine:

 

Update will come soon!

[Jamal 2]

Putting together continues:

 

Machined Mi flywheel, kevlar clutch:

A little bling-bling:

 

The BOV maybe enough:

[pablo 0]

Like it mate! Some nice pics of an XU10J2TE too for future reference!

[Jamal 2]

Made an extension to the heat shield:

 

Getting in:

 

My first idea was to lower the radiator to gain space for the IC:

[Jamal 2]

Then I decided to do this:

 

But to do that I had to buy these:

 

The IC fits great

 

Just had to pipe in

[Jamal 2]

I bought these on the Hungarian Ebay called Vatera:

 

Has been shotbalsted and powercoated

 

Refurbed Guttman alloys with Goodyear Eagle F1 GSD3's

 

Started the water circuit, used a solution that Hilgie used:

Edited November 16, 2009 by Jamal

[DanielWatts 0]

Nice work!

 

Looks mint

[Jamal 2]

Some brake things, 206 GTi 266 mm drilled rotors, 206 GTi brake calipers, 406 23,8mm master cylinder

(the rotors now changed between sides)

 

 

Started to wire in the engine.

Decided to put the ECU at the GTi's standard place, so I had to extend the wiring.

[Paulmac19 4]

Wow mate that car looks great keep the updates coming

[Jamal 2]

Some needed mods on the intake pipes:

 

A very little Volvo PAS tank

 

My temporary self-made downpipe(made with arc welding):

 

Test fitted wheel:

[Jamal 2]

Now my project thread will be real time.

 

Here I am at the moment:

[Jamal 2]

pablo, DanielWatts and Paulmac19, thank You!

 

Doing this job as a hobby, so I want to do it as well as I am able to

 

Now the engine is running, but have to solve a few problems. WG solenoid has to be changed. I bought a T-piece for the oil pressure sender, but it has got 1/8" NPT thread. I have to think about a solution because the sender is M10X1 threaded. Immo keypad a bit silly. After it blocks the system, the double relay starts to switch in and out. Rev counter isn't working.

Cooling system isn't as well working as I tought, so needed to redesign(I have got it in my mind now).

 

So there are many thing to do.

Edited November 16, 2009 by Jamal

[pablo 0]

I bought my car already converted and it was still a lot of work!!! For the oil pressure Ive simply got a standard gti sender which goes straight into the block. I dont really care about the pressure switch as long as I can see the pressure myself.

 

The keypad can be removed. afaik (Ive been told this, not tried it). With the car running unplug the keypad and you shouldnt need it anymore.

 

rev counter needs a modification, there is some info here about it.

 

If you want any info on cooling I can take some pictures for you of mine. Mine doesnt seem to have anything custom done and works really well.

[pablo 0]

did you have any problems with the PAS? Im quite tempted to fit it to mine if its not a big job.

[omega 82]

very nice work just watch those edges where the intercooler pipes go through

[Ludi 2 2 Cars]

It looks awesome.

 

I like it a lot.

[Jamal 2]

did you have any problems with the PAS? Im quite tempted to fit it to mine if its not a big job.

 

I'm in a better position then You guys, mine is left hand drive. Its easily fitted with the standard 406 pump, standard hoses except the high pressure one. It is made by a hidraulic shop. I've seen on some pictures, that the free space is very little on the right hand driven 205's, but I'm sure, someone who has fitted it can help You.

 

The cooling is not bad, just a bit blurred. I will use a joiner(the thing at the back of the block) from an automatic XU10J2, because it has got two normal holes and a small for the turbo. It is the same, fitted to XU10J4TE.

 

Will use an alloy distributor hose for the turbo and oil cooling because now I using the standard rubber hose, cutted to length and turned 180'.

Edited November 16, 2009 by Jamal

[Jamal 2]

very nice work just watch those edges where the intercooler pipes go through

 

Yeah, I know it's not the best. I used some rubber sealant on the edges to smoothe. It will get some door edge protector. Hope it will solve this problem.

[sonofsam 5]

Great job Sir! well done !

[Jamal 2]

Great job Sir! well done !

 

Thank You!

I'm doin' my best

 

Can You tell me something about this?

Edited November 16, 2009 by Jamal