[Engine_Work] Not A 205, Other Frenchie. Rowan's Saxo 1.6 16V Turb

[Rowan 1 1 Cars]

I'll post up my project thread here, even though it's not a 205.

I'm still working on it, so any remarks/comments/advice is greatly appreciated.

First I started collecting parts

Mocal oil cooler

JP4 camcovers

Megane 225 injectors (390cc)

Uprated gear links

Intercooler, oil catchcan, slim fan and 200CP sportcat

Vems 3.6 standalone with wideband lambda and on board MAP sensor

Re-looming the bugger

And redesigned the woofer case to hold the 79Ah battery

(will post more fotos when it is upholstered)

boost control solenoid

MSD ignition thanks to trackdayparts.nl

Got a crappy 16v lump for the rebuild. And while I was at it, got me a hoist and an engine stand.

All the nuts & bolts are being replaced by stainless ones.

New stainless 2.5" mufflers and flex part

New valves, valve seats, seals, skimmed and vacuumtested

Freshly honed block

Since the block and head were ultrasonicly cleaned they could use a fresh coat of paint

I've sanblasted some bits in the workshop at our service department.

The mechanics there were curious as always to see a pencil pusher getting his hands dirty :hug:

 

[Rowan 1 1 Cars]

Genuine HKS SSQV 4, order at an offical HKS dealer

Clutchkit from the friendly and helpful Clutch-Specialists

And the Tial MV-S wastegate from DP-Engineering

Stainless for various brackets and such

But more of notice, I've finally started with the actual build!

Baked myself an oilpan

Ready to get cracking

Fitted fan and string-fitted intercooler

Interior gone and loom ready for sorting out

Out with the old

Enginebay ready for cleaning and painting

The garage at the moment

[Rowan 1 1 Cars]

• 

  

  

  

• 

  

  

• New track rods and link rods

  

  f***ed bushes, so replaced them with powerflex

  

  Refurbished the strut

  

  Started welding

  

  

  

  Figured out the wastegate runner

  The welds aren't the prettiest but they'll do the job, quite content with them since I'm just a desk monkey

  

  

   

[Rowan 1 1 Cars]

welded up the bad boy

Yes I wrapped the alternator cover and dipstick in heat reflective film.

Old firmware

Updated to latest firmware

It is a bit overwhelming as a first time dealing with this sort of thing.
But it's just another challenge

[Henry 1.9GTi 36]

nice! very nice.

 

watch out for the megane injectors. I had to replace mine at just 30k miles.

[Rowan 1 1 Cars]

Cheers!

 

Thanks for the heads up!

[Kezzer30 40 1 Cars]

Teach me!

[Rowan 1 1 Cars]

What do you want to learn?

[welshpug 1,666]

poor little gearbox!

[rallyeash 155]

Fair play. Impressive build. Indeed poor gearbox! You looking at going BE4?

[Rowan 1 1 Cars]

Mechanical sympathy will be key for a while.

I still have a spare box I can throw on, but I will be looking into a BE4 (waiting for the Constella to come up with a kit for a level engine)

However, since buget is tight from now on (bought a house) it will take some saving to begin the conversion.

 

Is there anyone on this forum who has experience with Vems? I'm trying to get a base map set up and could use some pointers/advice.

[welshpug 1,666]

looking at the fabrication skills you have, you wont have any trouble making the BE4 conversion yourself, no need to buy stuff.

[Rowan 1 1 Cars]

[td_dan 7]

really stunning and such attention to detail look forward to more updates

[calvinhorse 870]

Top work, looking really good!

[2052NV 24]

wicked! I love lots of photos!

Edited August 28, 2013 by 2052NV

[TT205 42]

Brilliant - very impressed!

 

As for Vems - post a topic in the Aftermarket Engine Management Systems section

 

http://forum.205gtidrivers.com/index.php?showforum=42

[Rowan 1 1 Cars]

Thank you all!

 

And I'll post a topic in that section

[Rowan 1 1 Cars]

[Crocksy 0]

very well done mate!

[Rowan 1 1 Cars]

A wee update.

When it first started it didn't idle and the 4th cilinder wasn't really puttin as much effort into it as the other 3.

Hence I decided to clean the injectors and sparkplugs. Altered some bits in the Vems and started it up.

All 4 cilinders purring and it even idled! (at +/-1200 rpm and only when warm )

And so the first test around the block came to be :oops:

Even though it's not as smooth as it could be, it already is a huge difference.

I've set the wastegate to .5 bar boost for safety reasons, since it's not really mapped.

This also means that de screamer pipe comes in really fast, and that sound is just pure porn. Which is followed by the HKS bov, and I feel like a little kid again

New tires are being fitted as we speak, then it's of get aligned and the wait for the 1st october when it is getting mapped bij Pieter at DP-Engineering.

A few pics to round it off.

[Rowan 1 1 Cars]

Teaser:

(not dyno'd, running on a safe basemap)

[Rowan 1 1 Cars]

After a long day tinkering, mapping and testing a result has been achieved to my satisfaction. Again, I'm not in it for the numbers, for me it's about the driveability and fun (building and driving)

195HP en 270NM @ 0.65 bar

That was all we could get out of the tiny T2 turbo, however I''m very pleased with the result. The power is right where I use it and maybe the chocolate MA box will last a while now.

The drive home from DP-Engineering put a smile on my face from ear to ear

Even got to test how it holds up in traffic :homme: Temperature just above middle in the gauge. The clutch is some getting used to, but works very well.

Very pleased with DP-Engineering (Pieter), excellent service!

When I arrived we sat down for coffee and had a chat about my build and other related stuff. Then went to check everything and came across the stepper (iac) which didn't cooperate. After we've been upside down in the car checking the wiring from the vems behind the dash we came to the conclusion some wires have been switched around (my bad). Fixed it and Pieter started the mapping.

After a few minutes Pieter said the standard iat sensor was too "slow", which would affect enrichment and timing in a negative way. So off with the boost piping and het welded up a bung for the new "fast" sensor.

Anyway, after all this tinkering we were a few hours in before the real mapping could finally start. He was working his magic and we came to a good result.

Pieter was impressed with my driveway-build but expected a bigger turbo when he saw the engine with external wastegate, boost controller, etc.

He recommended a TD04 for more breathing room and performance (whilst still on a budget).

For now I'll just enjoy driving the thing and fixing a few minor things

And the pics:

[2052NV 24]

Thats awesome must be a blast to drive!

[2052NV 24]

Also how awesome does the wastegate sound??