205 Turbo (1.9 - 8 Valve)

[Reebmit 51 4 Cars]

 

This is an original 1.9 GTi but arches are off at mo, so picture doesn't show them.

 

I'm getting this particular car ready for some track abuse this summer, had a 2.0 turbo in (previous owner) which was very heavy and not very well done to say the least. Decided to rip engine out and put in one of my standard lumps and go from there as a basis. The engine is in and am just tidying up wiring, real mess. I should have it piped up and go for a start over coming weeks, all depends on time, back at work on Monday! painful.......

 

 

This is a good strong standard engine, I gave it a top end rebuild a while ago and is a good starting point. The plan is to turbo (T28) this motor (on low boost) and get everything in place, management, intercooler, pipework etc etc.... and also build up a strong engine alongside to swap out once done. Then plan is to increase boost etc.... on stronger motor. I have to say I like to try and keep my projects running if possible as its far to easy to left them drift on and on in the corner of the garage and its very hard sometimes to get motivation......

 

Before putting this engine back in I made sure I fitted a flywheel/ sensor from the outset as I don't really like the bolt onto the front pulley option.

 

I will try and get as many pics up as I can and will try and keep you posted with the ups and downs along the way.

Edited January 1, 2014 by Reebmit

[Reebmit 51 4 Cars]

Hopefully guys you can bear with me on this one, on a catch up really so trying to find some pics of earlier on.

 

 

2.0 Turbo engine out and christ what a weight! cannot lift on my own and in comparison can lift 1.9 ally 8 v into boot of a car without too much problem....one of the main reasons for the change.

 

Engine bay once motor removed, not too bad but needs tidying, no rust on inner wings so that saves a little work. This car is not going to be a concourse show car but a good usable track/road car that can be used, abused and enjoyed

 

Edited January 1, 2014 by Reebmit

[Reebmit 51 4 Cars]

Not getting too involved with interior at mo but picked up this SD cage other day as you may have seen in one of my other threads, quite a laugh that one, luckily enough to get the weld in plates which makes life a little easier. Pug in background not the car in this thread.

 

[Reebmit 51 4 Cars]

Just found an interior shot which not too untidy will be worked on in due course. Was going to nip out and take a few more shots of car but rain is hammering down at mo

 

 

Hopefully from now on the thread will follow a normal timeline

[Reebmit 51 4 Cars]

Just nipped to the shed to rummage through some bits that came off the 2.0 conversion, got just what I needed for a little further down the line. I know this fits behind the front bumper/valance as its been there before.

 

 

Intercooler in not bad condition, needed a few of the vanes straightening out

 

 

Main filter pipe which has new filter on, saves some cash, have quite a few other similar sized ally pipes/bends along with quite a few silicone sections, should aid the installation later.

 

 

This box was buried under a big pile of junk! got a few few more goodies in here....again stuff that came off the 2.0 conversion

Edited January 2, 2014 by Reebmit

[camgti 56]

Nice work!

 

Seems a nice car to chop up!

 

Be interested to see how you get on. Always good to see tidy work!

 

Cam

[Reebmit 51 4 Cars]

Thanks Cam appreciated, will endeavour to get it right. This car is quite tidy but will modify sypathetically, I will only do things that can be reversed. The worst thing that will be done is welding in cage plates so nothing too drastic. Certainly no major chopping ..... I'll keep you posted.

Edited January 4, 2014 by Reebmit

[Reebmit 51 4 Cars]

Well managed to get out today and do a bit more work in engine bay. Miles came round to collect a spare engine I had kicking around, and had a good natter as usual.

 

I thought I would make a start on the wiring which I knew was bad but ended up being far worse than expected:

 

 

Ummhhh thats nice.......... NOT,,! One of the first jobs was to fit an existing engine/ECU loom I had and all went well there. Next job was to find the two brown plugs from the fuse box ands thats where the fun started. In the end I managed to find this mess which had been converted for the 2.0:

 

 

This all harps back to one of my other posts for bad alarm installations......these pics relate to a past engine installation

 

Plan now to find a link loom or looms that goes from fuse box to my two brown engine loom plugs.

 

Couldn't resist but show another lovely pic:

 

 

once the mess is sorted I'll put up a few pics of a neater installation...hopefully. The fuse box area always seems to be messy on these 205's.

 

 

 

 

[andy-mac 4]

thats the next project for mine fit turbo engine , not looking forward to the wiring

[Reebmit 51 4 Cars]

Would be good if you can stick to the original 1.6 or 1.9 and turbo that, such a nice conversion.

[Reebmit 51 4 Cars]

Managed to get a couple of hours in tonight, bit more pipe work, cables etc....

 

Sorry no pics tonight but started tidying the wiring inside the car then removed the front lighting loom through to the fuse box. it was in pretty bad condition so will probably be looking for another soon.

 

I think I will go for the Simtek multi plug in the engine bay and get rid of the badly corroded brown multi plug....... I had a good look through welshpugs link on Brown multiplugs, thanks for that Mei, very informative

[Miles 331 1 Cars]

You can do away with it all together, Not really needed as you can wire everything direct bar the water and oil temp so just a 3 pin connector needed

[Reebmit 51 4 Cars]

Cheers Miles sounds a better option will look at that. Have you got a spare expansion tank hose to back of engine? haven't got any left, the one I did have is shot...

[Reebmit 51 4 Cars]

Got a quick pic, the standard 1900 coming along well, should be running soon but away this weekend so I'll have to wait before I can get back out in the garage

 

 

 

[Reebmit 51 4 Cars]

Less wires now, got rid of all the crap so can start tidying these looms up now!

 

[Miles 331 1 Cars]

Might have, taking the engine out of a breaker tomorrow so should have the other loom too

[Reebmit 51 4 Cars]

Sounds good Miles, I will catch up when I'm back. Would be good to get wiring bits sorted and any other little bits I'm lacking....can you also check out the oil filler to sump hose with the take off, maybe in okay condition??

[Reebmit 51 4 Cars]

Popped round to Miles on Friday for a catch up and to get a second hand loom to connect to brown plugs under heater, great result Miles! went in perfectly and the front lighting loom also rectified quite a few issues. One was the wiper motor loom running along the bulkhead, it had a massive choc block, don't know why but it did! so this loom does away with joining that mess which is much preferred... The fuse box area is a lot neater now, will post a pic soon.

 

Thought I would check the condition of my sensor sub loom for engine and it had definitely seen better days:

 

 

So I thought what a nice Sunday job, make a new loom. I had run out of good female spade connectors but found some cheeper ones that would suffice and have also heatshrunk them to avoid any potential issues. I'm not going down the brown connector route and have connected direct to existing loom, this should hopefully should eliminate any problems later on.

 

 

When joining wires I like to splice them together and wrap single strand of copper wire round then solder joint. I then used solder sleeves as per next picture, these shrink down, extra solder the joint and seals against the wire (blue band), they work so well, never had a problem using these.

 

 

 

So the joints and loom are now wrapped and fitted and should hopefully do the trick...All in all a good day, did loads of other jobs too.........have now come in for a glass or two and check out what you guys have been upto

[Reebmit 51 4 Cars]

Managed to get a few hours on it today, running sweetly now which is where I need it to be before carrying out further engine work.

 

Next stages to get to a usable standard:

 

1. Finish off engine bay, restore fan loom, general loom tidying/fixing.

2. Fit front bumper, grill.

3. Lower suspension using parts from other car I broke a while ago.

4. New discs, pads, standard for time being.

5. Fit cage

6. Transfer Prodrive bucket seat/harness.

7. Restore/re-spray tailgate

8. Restore all exterior plastics and re-fit.

9. MOT.

 

Once this little list is done I can concentrate on getting more parts together for the turbo conversion although thats an ongoing task as we speak.

[Reebmit 51 4 Cars]

Hi all, been a while since I've had a chance to get on with car, been doing bits in between everyday life/kids/work! so will endeavor to get some posts up.

 

Quite a few jobs done including cage, seats/harnesses, rear beam, rear underside restored, rear brake caliper refurb etc... bear with me and I'll get some pics up........

[Reebmit 51 4 Cars]

Continued to strip interior and found floors etc really solid.

 

 

 

Prepped cage plates and shell

 

 

 

All welded up, mig played up a little but clean and strong, do miss having a tig. Cleaned up well and with a little addition of red oxide all done. Having lack of rust helped .....

 

 

 

 

 

[Reebmit 51 4 Cars]

Managed to get hold of some tidy seats off the Bay and a few weeks later a cracking deal on some harnesses, so saved a few quid, always good to keep the other half happy

 

 

 

Managed to modify the original runners so keep the sliders which is ideal.

Edited September 15, 2014 by Reebmit

[Reebmit 51 4 Cars]

The rear underside again was almost perfect just needing a wire brush, rust preventer and paint but the beam was totally knackered.

 

 

 

 

 

Quick search on forum managed to get a really sound beam that looked like it had been refurbed sometime in the near past, really smooth and no play........but just need a good clean up and paint as it was looking really rough. Also did a deal for the solid mounts which was greatly appreciated

 

 

 

 

 

 

 

Car back on ground for some motivation, but will be back up soon enough.

 

 

 

 

[2052NV 24]

Nice one man!! that looks like a super tidy shell when compared to 90% of the other build threads, I do feel sorry for you fullers in the UK with your salty roads, no such issues in little old NZ

 

And dam your car actually looks really good without the trims on

 

Are they Saxo VTS wheels btw??

[Reebmit 51 4 Cars]

Thanks Rob, yeah shell is really good, very pleased .....

Good old NZ, we were going to be out there over the past year (Ive got dual citizenship with UK/NZ) but things happened to prevent it, I was really looking forward to it! Oh well, maybe another year.

I am going to leave the arches off as, like you I think it looks right. Yes, Saxo rims which I only have on temporarily but may run them for a while until I get some more.