Advice On '6 Conversion

[james306 0]

Not 100% if this is the best place to post it, but engine work wouldn't let me start a new topic so here I am!

 

I have just aquired an XU10J4RS engine, I'm weighing up my options and in two minds as to what to do with it! It's becoming increasingly tempting to drop her into my 205 and I have read up a bit in the past but don't want to miss anything.

 

To my understanding I need

 

XU10J4RS engine

GTI'6 brakes + m/c (better to be safe)

Some sort of exhaust linkage/custom manifold

Unlocked ECU

Alterations to wiring loom

Speedo converter depending on gearbox

Gearbox (how good would the original 1.9 box be?)

New radiator?

 

I have also been told you have to trim the exhaust channel to allow for the angle on the downpipe, this is where I wondered if a custome downpipe/linkage would do the trick or if it's a room issue with the beautiful creation that is the XU10J4RS's exhaust manifold. I have seen conversion threads in the past that have no mention of trimming out bodywork so hoping this could be the case.

 

Any comments on what I have probably missed, things that could bump the conversion cost up that I have overlooked etc as if I want to do the conversion I need to start the ball rolling now due to an upcoming change in career.

[miamigtimark 3 1 Cars]

Do a search.

I used Nikaliaths journal . (its in "engine works").

[allye 530 3 Cars]

All you answers have been asked to death one thing I wasn't completely aware off (and found out today) You don't need a new radiator you need to make a bracket to make it sit lower to avoid the inlet. You don't need the big brake, I'm using rebuilt 1.9 girling calipers and they will be up to the job!

[Spiky 37]

Not 100% if this is the best place to post it, but engine work wouldn't let me start a new topic so here I am!

 

I have just aquired an XU10J4RS engine, I'm weighing up my options and in two minds as to what to do with it! It's becoming increasingly tempting to drop her into my 205 and I have read up a bit in the past but don't want to miss anything.

 

To my understanding I need

 

XU10J4RS engine

GTI'6 brakes + m/c (better to be safe), not really needed

Some sort of exhaust linkage/custom manifold, modify 205 downpipe or get a 306 decat and cut that up

Unlocked ECU defo

Alterations to wiring loom, simples

Speedo converter depending on gearbox you need a vss with both electronic and mechanical drive, s16 has this

Gearbox (how good would the original 1.9 box be?) 1.6, 1.9 or gti6 will be fine

 

New radiator? not just needs a little altering

 

 

I have also been told you have to trim the exhaust channel to allow for the angle on the downpipe, this is where I wondered if a custome downpipe/linkage would do the trick or if it's a room issue with the beautiful creation that is the XU10J4RS's exhaust manifold. I have seen conversion threads in the past that have no mention of trimming out bodywork so hoping this could be the case., i have modified my bulkhead, but you can just alter the bottom fork, and drop the drivers side and gearbox mount down

 

Any comments on what I have probably missed, things that could bump the conversion cost up that I have overlooked etc as if I want to do the conversion I need to start the ball rolling now due to an upcoming change in career.

 

 

hope that helps

[Miles 331 1 Cars]

A proper list should be

 

1. Custom Modified loom routed under the header tank as the OE position is too close to the exhaust manifold, even 8v ones suffer heat damage. with unlocked ECU, Rich Walker does these at a fair price if locked.

2. Modified exhaust manifold & D/P but avoid the phase 1 3 piece system as it's too small a Dia.

3. VSS sensor, 306 XSi, S16 use them or new £40.00

4. Any BE3 or late BE1 gearbox is fine, Late BE3's can be used but the diff really wants changing as the offset is different

5. New Cambelt, Water pump and tensioners along with Service Items

6. BBM GTi6 Silicone hose set, Saves mucking around with std pipes

7. Space Pedal box up slightly and reseal along with trimming the cam cover slightly.

8. S16 Oil pressure Sender or adapter to use 8v sender (Unless 1997 engine) which you then need the oil temp sender in the sump.

9. Larger fuel banjo for supply fuel line to engine.

10. Re-route lower fuel pipes and I use heat shielding around them for extra safety

11. Re-seal cam covers and carriers, these always leak and with the engine out is dead simple

 

Things like Modding the bulkhead is not needed, dropping/tilting the engine is just a bodge, rad stays in the same place unless it's a nasty cheap pattern one,

 

I;ve normally got the odd one kicking around at work so by all means pop up.

Edited April 14, 2011 by Miles

[shalmaneser 26]

A proper list should be

 

1. Custom Modified loom routed under the header tank as the OE position is too close to the exhaust manifold, even 8v ones suffer heat damage. with unlocked ECU, Rich Walker does these at a fair price if locked.

2. Modified exhaust manifold & D/P but avoid the phase 1 3 piece system as it's too small a Dia.

3. VSS sensor, 306 XSi, S16 use them or new £40.00

4. Any BE3 or late BE1 gearbox is fine, Late BE3's can be used but the diff really wants changing as the offset is different

5. New Cambelt, Water pump and tensioners along with Service Items

6. BBM GTi6 Silicone hose set, Saves mucking around with std pipes

7. Space Pedal box up slightly and reseal along with trimming the cam cover slightly.

8. S16 Oil pressure Sender or adapter to use 8v sender (Unless 1997 engine) which you then need the oil temp sender in the sump.

9. Larger fuel banjo for supply fuel line to engine.

10. Re-route lower fuel pipes and I use heat shielding around them for extra safety

11. Re-seal cam covers and carriers, these always leak and with the engine out is dead simple

 

Things like Modding the bulkhead is not needed, dropping/tilting the engine is just a bodge, rad stays in the same place unless it's a nasty cheap pattern one,

 

I;ve normally got the odd one kicking around at work so by all means pop up.

 

This is an excellent list, but I'd also add...

 

- Group N lower gearbox mount and solid bush - Things really are very tight and you want to prevent the engine rocking as much as possible, which these two will do. I'd also advise BBM Group N mounts throughout, just because you can do them in one hit.

- 405 speedo cable, longer than the 205 one to prevent heat damage from the manifold

- You'll need to take an angle grinder to the slam panel, fairly minor though

- Generic Pug throttle cable, 205 one is far too short

- If you're going to keep the power steering I'd advise using the Xsara PS reservoir.

- You'll need some 8mm and 10mm fuel hose, as well as an 8-10mm convertor. This can also be used for the PS fluid, as you'll need to replace some hoses as they're too short

 

All this has been discussed at length, see my thread for details, as well as many others.

[james306 0]

Thanks for all your advice so far, the XU10J4RS is going on hold for the time being, but I will start collecting the parts to complete the conversion and look into getting a winter runaround while the conversion takes place!

 

I will definitely be avoiding trimming bodywork/bulkhead as much as possible so group N mounts all round doesn't sound a bad idea! How do people who have done find vibration?

[monkee87 2]

- If you're going to keep the power steering I'd advise using the Xsara PS reservoir.

 

Can I ask why?? I'm thinking of doing this conversion and if I do, I'll be using a 205 P/S rack with the 306 pump.. I want to keep the original power steering reservoir where it usually is on a 205 as there is plenty of space there when you fit a '6.

[Miles 331 1 Cars]

Looks better I think where the Jack would normally be and it gets in the way where it is normally as the Air filter sits there unless you use a water sucker up'er'

The 306 ones OK too

[welshpug 1,657]

keeps the pipework neater, seen one used on an 8v rally car too.

[monkee87 2]

Where do you put the jack if you put the reservoir where the jack goes?

A friend of mine has a '6 in his 205 and has a cone filter attached straight to the throttle body. Iirc, there was loads of space behind the headlight because of it. Just seems like the logical thing to do is keep the 205 one so I don't have to loose the jack which I may actually need one day!

[welshpug 1,657]

under the seat like a CTI