[Engine_Work] White 205 Uk Rallye 1.6 16V

[johniban 59 1 Cars]

As some people know callum had his 205 rallye up for sale a while ago, and for some time ive been pushing him to sell it to me, well the day came and i snapped it up.

i have another 205 gti6 project too so the rallye just sat at the end of my drive with a car over it for about 3-4 months taking it out for the occasional clean.

Edited February 11, 2014 by johniban

[johniban 59 1 Cars]

i want to try and keep it original as possible but its already had a 1.6 8v injection conversion witch wouldnt pull the skin of a rice pudding,

 

so i decided to fit a 106 gti engine.

now i didnt want to just buy any old engine and chuck it in without knowing history about it,

as it happens i have a 106 gti daily runner that i have had for 3 years so i know the engine is sweet, i recently replaced the cambelt and a rebuilt the gearbox 2 years ago so it was a good idea to use the engine and box i know are good.

i was a bit gutted removing the engine from the 106 ive had for so long, but i will probably put another engine in the old girl.

 

so old with the old

[johniban 59 1 Cars]

and the doner..

 

engine out...

 

had to swap everything over from the old engine, mounts ect and grind down the offside moun to fit round the cam covers

the two cars together

[johniban 59 1 Cars]

engine in

went surprisingly well considering i was on my own, no real drama

 

 

then it was down the the hardest part of the conversion, the wiring, witch turned out in the end pretty easy.

i thought the ecu had locked itself but it turned out i just has the 12v to the fuel pump and coil wired wrong as i kept loosing voltage on cranking, but now its all running.

 

then spend a good hour or two cleaning up the loom and fitting conduit and tidying it up.

[johniban 59 1 Cars]

i then modified the 421 manifold as the subframe is in the way, i thought of the easy route to route it under the subframe but it thought it may look a bit pikey so i went the right way up and over, its not perfect put its doing the job, i do need to sort out a decent exhaust as its still got the standard exhaust and must be pretty restrictive,

[Lowercase 56]

looking good john. ive always thought that little rallye needed a 16ver in it. please paint cam covers lol. its upsetting my ocd!

 

ah man i want another 205 now...

[johniban 59 1 Cars]

i need to sort them out as they keep leaking and filling spark plug holes with oil, im thinking of getting the plastic covers as they have seals

[rallyeash 155]

Nice work. Need a normal plate IMO though.

[dcc 855]

I need to see a photo of how youve done the manifold

[johniban 59 1 Cars]

I need to see a photo of how youve done the manifold

 

 

Been waiting for someone to ask that! haha, ill get some pics up, that was the hardest part i think todo, i wasn't sure weather to go under or over the subframe, it was a little harder as i have a 421 and it finishes into the 1 quite close to the subframe, i chopped off the 421 just under the sump then luckily the old down pipe witch was new was the same ID/OD as the manifold so i used to it go over the subframe.

 

unfortunately the only exhaust i have to match up to it is the standard one with is tiny and really restrictive so i need to make up one

[johniban 59 1 Cars]

need to make a decent exhaust for it when the weather gets better ill knock up a stainless jobbie with a nice silencer, flexi section to stop the mounts cracking and a lambda port as it runs lumpy atm

[MiniGibbo 142]

smashing through with this..!!

 

looking ace, below subframe is better for 'flow

[johniban 59 1 Cars]

I think I may change it to below the subframe to be honest as it's pretty akward making up bends around the subframe and gear linkages

I was worried about ground clearance having it under the subframe but the cars never going to be slammed so shouldn't be a problem

[welshpug 1,657]

I would go over, especially as you have slready made the manifold.

 

It wont restrict them much if at all if done properly.

 

You dont see mk2 escorts with exhsusts hanging under the live axle do you, they always go up and over

[johniban 59 1 Cars]

in looks nice and free flowing all the same size pipe up untill the end of the manifold, but the center section is tiny.

[MiniGibbo 142]

From what I've seen the up and overs seem to crack a lot too..

 

If it works leave it alone but is simpler straight haha

[johniban 59 1 Cars]

The reason most exhaust crack is the lack of flexi section witch I find with the 106 pugsports I've strengthend a few systems where the mounts have cracked or fell off. The back box that was on the Rallye was all cracked I've welded it up for now but I'll be changing the box to something more subtle soon

[johniban 59 1 Cars]

The trouble with the under I had Is getting It to actually go under as it sits pointing the subframe so would need to get a couple sharp bends in there to clear the frame

[BC Devile 3]

Also very interested to see your manifold! Guess your running a standard subframe?

 

That rallye was on ebay as a non runner a while ago??

[johniban 59 1 Cars]

yep car is completely standard apart from engine, gearbox and shocks, and unfortunately the interior.

 

Yes it was callums (lowercase) from this forum i bought it from him.

 

was a non runner but he and i knew the problem with it and we fixed it when i picked it up

[MiniGibbo 142]

what mani you using the oem. I had a couple for mine before we got one that actually fitted (all aftermarket 421)

 

mines an Ashley and flows low enough under the sump to get a straight shot past the subframe.

[johniban 59 1 Cars]

havent got a clue on the make, its a stainless thats not been coated black, think its probabky a cheapo one i only payed like 20 quid for it years ago. its a 421

[johniban 59 1 Cars]

Today got a little done, managed to wire up the rev counter witch works a treat! got the idle issue sorted, though it was because the lambda was wired in but turns out it was because i didnt have the air temp sensor plugged in, because i had moved the ecu over to the battery side i needed to lengthen the wire of the air temp plug. now idles awesome and goes like a rocket!

 

also as my 106 had stainless fuel lines through i used a small length of hose for the fuel feed just to smarten it up a little

 

then it started raining again!! starting to get really annoying now! only having spent around 4 hours on the car so far over 4 days due to it non stop raining

so the rain stop for ten mins

 

now the coolant system would never bleed properly and the stop light would come on before the fan kicks in so i decided to sort that out.

the rad is obviously too small for the engines needs so i fitted the item from the 106 gti, bled out straight away and the fan comes on with no stop light!!

[johniban 59 1 Cars]

Knew that hole in the scuttle panel was for something! haha

 

 

witch means i dont need a coolant bottle

witch means i have a decent place to mount the ecu for now untill i mock something up

 

[johniban 59 1 Cars]

Radiator is deffo a snug fit but the fan switch is the same so plus straight on but doesnt mount up correctly so i will be making up new mounts for it to secure it and drop it a little lower when the weather gets better.

 

 

about 12mm of room between rad and manifold/oil filter