Xu5/9 Inlet Onto 2.0 Turbo

[danpug 1]

As above. I've read a couple of posts about it but has anybody done and what do you need to do?

[Anthony 1,003]

You'll need to reshape the inlet ports to match the XU5/9 manifold (squarish manifold ports, roundish head ports), and if you're retaining the standard 2.0T management, you'll need to work out some way of retaining the standard XU10 throttle body really, or heavily adapting the XU5/9 one for the various sensors and ICV.

 

The former isn't too difficult and is what needs to be done when doing XU10J2 head conversions on XU5/9 bottom ends/management (as I have on my car) although you'd ideally want the head off the car so as not to get swarf everywhere. The later someone on here has done - from memory it was about 4-6 months ago if you want to do a search.

 

I've not personally done it on a Turbo engine so not sure what other issues will arise. Only other thing I can think is that the throttle body ends up in a different place and facing a difference direction, so any existing pipework from the IC to the TB will need to be changed to suit, and possibly some of the wiring extended a few inches.

[Tom Fenton 1,542]

I'll go as far as to say, junk the XU10 head as well and fit the GTI one. The chambers can be easily opened up to lower the CR. OK you lose a little in valve size. But the standard turbo cam is pretty poor, the GTI cam is a better choice.

[pablo 0]

you can run a non turbo cam tho in the turbo head? The cam in my car isnt a std turbo one. No idea what it is tho!

 

Ive a spare head and a gti inlet manifold here but never got around to doing anything with it. Not sure there are really gains to be made I think someone worked out the turbo TB (while smaller than a GTI one) was able to flow plenty of air.

[danpug 1]

I'll be running an xsi 8v cam, haven't bought any pipework yet so that wouldn't be an issue. I just don't like std inlet, its messy. Could the inlet ports not be matched to the head rather than the other way around?

[Anthony 1,003]

Could the inlet ports not be matched to the head rather than the other way around?

Without adding metal to the manifold, no, not really - if you have an old XU5/9 inlet gasket handy, put it over the XU10 head and you'll see the extent of the problem and what metal needs to be removed. I'll have a look at home later and see if I've got any pictures of my modified XU10 head before I fitted the manifold.

[danpug 1]

That'be good thanks. Does anybody know what extra sensors (essential ones) there actually is on the 2.0t inlet?

[pablo 0]

one is listed as a "reheating unit", one is obviously a throttle position sensor, no idea what the other one is tho.

 

EDIT:

1240 Inlet air thermostat

1270 Throttle housing heater resistor

+ TPS

Edited November 18, 2009 by pablo

[danpug 1]

Thanks Pablo. I'm guessing the heater isn't really needed? It would be easy enough to fit an inlet temp sensor (the same way Tom did his) and i assume the xu5/9 tps would be compatible?

[Anthony 1,003]

i assume the xu5/9 tps would be compatible?

No, as the XU5/9 TPS is actually a simple switch for throttle closed (for fuel cut) and WOT (for enrichment). XU10 is a proper variable throttle pot.

 

Easy enough to make an adapter plate to attach a proper TPS to the side of a XU5/9 throttle body though.

[danpug 1]

Ok. So the head ports need matching, inlet temp. senso would need fitting and a plate would need making up for the tps. Anything else? Theres a little black thing near the engine mount that connects to the throttle body, the actuator and other pipes, any idea what this is and if its needed?

[pablo 0]

boost controller mate.

[danpug 1]

Do i need to retain it? Planning on running an electronic boost controller.

[jonnyturbo 3]

if you decide to go along with this mate make sure you get lots of pictures and info on how you did it any if you can feel any gains etc!

[pablo 0]

Do i need to retain it? Planning on running an electronic boost controller.

 

youll still need the feed for the boost controller, it will just replace the oem solenoid and keep the same piping.

[danpug 1]

Where would it go to on the xu5/9 tb though? I'm a bit confused as to what happens with it when the engine goes into a 205 anyway! Jonny, if i do it i'll give all info, still undecided at the moment.

Edited November 18, 2009 by danpug

[pablo 0]

Well there are two feeds needed. One for the ecu which is after the throttlebody. And one for the boost solenoid which is before the throttlebody. You could drill and tap the manifold or T off an existing feed.

[danpug 1]

So what did you do with yours on the std inlet? I can't find any pics/info about it, maybe i'm looking in the wrong places!

[pablo 0]

vac connections I have are:

 

on side of manifold, between tb and head:

- brake servo pipe

- dump valve pipe

(You could T these I guess off the servo pipe in XU9 manifold)

 

on top of throttlebody:

- ecu map sensor, pipe runs straight to ecu

- fuel pressure regulator

(You could T these I guess off the FPR pipe in XU9 throttlebody).

 

just before throttle body:

- one pipe T'ed. One to boost controller solenoid, one to boost controller control unit. (Im using a gizzmo boost controller).

 

You would need to transplant the TPS over onto the XU9 throttle body.

 

Would I be right in thinking because there is a map sensor the ECU should be able to work with the different sized throttle body without remapping?

[danpug 1]

I'd imagine it'd be fine, Henry Yorke uses this management on his engine so i'm sure its capable. Thanks for your help with the vac connections.

[pablo 0]

no problem, be interested to see how you get on!

[danpug 1]

Looking through Jakobs thread: http://forum.205gtidrivers.com/index.php?s...50603&st=10 he has done this modification and modified the inlet only: http://img218.echo.cx/img218/7008/42dn.gif. He said there is still a little on the head that needs matching but when this thread was wrote he hadn't done that. I wonder if leaving that little bit on the head will affect performance significantly or not?

[pablo 0]

nice link in that thread too:

 

http://www.aussiefrogs.com/forum/showthrea...mp;highlight=T3

[jonnyturbo 3]

thanks pablo, can you see anywhere in the post if he has had to modify that turbo to fit the tt manifold? looked for the turbo on ebay and there £800 i think brand new

 

 

also we need some sort of list that shows mods that can be done to the 8v turbo engine thats effective and worth doing and what power gains etc.

Edited November 20, 2009 by jonnyturbo

[pablo 0]

I think if I was going to change the turbo Id get someone to make me a manifold, and fit a turbo from an FQ300 evo or something. Good for 350bhp odds and cheap to come by. Cant be that dear to get a manifold made I wouldnt have thought you can buy kits with lots of bends etc and you make up what you want. Just need someone handy with a welder. Anything has to be better than the oem one.

 

Id also considered making an elbow to bolt onto the std manifold, and relocate the turbo over where the 16v turbos go (close to the coilpack) but with a T28 flange on it. Fit whatever you like then

 

But this is all a little OT. Ill take some pics of the XU10 8v head and the XU9 manifold I have if anyone is interested?

Edited November 21, 2009 by pablo