My 205 XU10J4TE (T16) install and other mods

[20five_t 1 1 Cars]

I thought that I would start a topic to show some of the work that has been done to install a 405 T16 engine in my 205. The car is still a work in progress - a few pics of the car before the work started are below (if I've inserted them right). 

At the time it was a 205 1.9 GTi with a turbo technics upgrade that had been installed since the 80s.

When the head gasket went I had decided to rebuild the engine and install emerald/omex until I spotted a XU10J4TE for sale.

 

 

 

 

[20five_t 1 1 Cars]

This was the 405 T16 engine when I bought it.

 

 

 

Engine bay with the TT engine removed and painted.

 

 

[jackherer 543]

Nice find! This is going to be interesting. The shell looks good too, the engine bay is perfect.

[barneys66 122 1 Cars]

As above - looks great. 

 

Was the brace part of the TT conversation, and have you kept all of the original parts..? 

[20five_t 1 1 Cars]

Yep, I've kept the TT exhaust manifold, TT turbo, 5th injector controller / loom, throttle body, intercooler, pipework, blown engine with low compression pistons etc.. 

 

When I bought the car it wasn't holding any boost.  It turned out that the waste gate actuator was set too soft. Once that had been tightened up a bit it boosted up ok.  I used a wide band AFR to play with the fifth injector settings - In the end it was working quite well until the head gasket gave up.   

 

I'm going to use some of the bits on do another 8v turbo conversion at some point,  maybe on more modern management rather than the 5th injector though.

 

I'm not sure if the brace is related to the tt conversion.

 

This is the old tt setup before it was taken out the car back in 2015.

 

 

 

 

 

[20five_t 1 1 Cars]

The main things on the car are (or are going to be):

 

Rebuilt T16 Engine. Standard Spec and Wossner Pistons.  Maybe remapped.

Rebuilt gearbox / Helix Clutch

Dash2 Pro 

SS Exhaust

 

Other changes:

Bilstein Group N Dampers / Eibach Springs

AP 4 pot Brake Calipers, pads and discs.

 

Miles who is on here has done the changes and is the brains behind it all.

I'll post some more pics of the progress in a bit. 

[20five_t 1 1 Cars]

Rebuilt engine.

wossner pistons 87mm re bore block

ARP Rod Bolts

Re cut valves, re face head

Main bearings

 

Recon starter and Alt.

etc.

 

 

 

 

 

 

 

 

Turbo was found to have a cracked exhaust housing. Eventually I found a new one and the turbo was rebuilt by Owen developments. Also got a new VAT 25 turbo just in case. I guess a lot of people upgrade these to more modern units now, but the variable turbine passage is quite an interesting feature.

 

 

Also operates at 1.1bar normally, but 1.3 bar with 'overboost'

Edited March 16, 2018 by 20five_t

[20five_t 1 1 Cars]

This all started as a project to 'just' rebuild the XU10j4TE and fit it in the 205. Over the years a few things have been added on.  At times I've  wondered if it would ever finish - I was looking back through the photos and the old TT engine was removed  at the end of 2014.

 

It seems like an MOT isn't too far away now though - fingers crossed. This post just shows some of the non engine stuff that has been done, the next one will show the engine stuff.

 

Brake upgrade with AP 4 Pot:

 

 

 

 

 

Bilstein Group N Dampers

 

 

Re conditioned sub frame and steering rack.

 

 

 

When the cables were run to put the battery in the boot the floor was revealed. Was a bit of a mess. Repairs in progress are below.

 

 

New deadening fitted.

 

 

Carpets back in

 

 

Drivers seat has been redone with a passenger seat on the old frame.

 

The dash was replaced with one out a very low mileage car. The old one had been cut up to fit boost and AFR gauges. The plan is to show AFR and boost on a digital dash now.

 

 

 

 

Dash2 pro has been connected up. It still needs setting up.

It means that we can use an electronic speedo and have vss for the overboost function.

 

 

 

 

 

I bought some phase 1 mirrors that can be adjusted from the inside - the ones on the car can't. Later I found out that they won't fit because the doors have been changed at some point and aren't phase 1 anymore. If anyone has some phase 1 doors for sale please let me know.....

 

 

 

 

 

Engine stuff I'll put in a separate post as this ones quite long now.

 

 

 

 

Edited March 17, 2018 by 20five_t

[20five_t 1 1 Cars]

 

last update for now. 

 

When the engine was stripped down there was some corrosion. Engine was rebored to 87mm and 87mm Wossner pistons were fitted.

 

 

 

 

 

 

 

 

 

 

 

 

This was how it looked in June 2016. 

 

 

This was in 2017.

 

 

 

 

some bling

 

 

 

 

This is a video of the engine running (without exhaust)

https://www.facebook.com/miles.horne/videos/10155911034071055/

 

 

 

 

 

 

and this is it almost back together

 

 

 

What's left now -  exhaust, Dash2 Pro Configuration, some coolant adapters then hopefully an MOT.

After that still need to paint the red Auto bonnet that's been fitted.

 

Also need to get it down the rolling road.  The map should be standard now - that means normal boost of 1.1 and temporary boost of 1.3 and roughly ~ 230 bhp.

Seems like there is potential to go a bit higher with the boost and a standard setup.

 

 

 

 

Edited March 17, 2018 by 20five_t

[JamPug 22]

Amazing !!

[ade 4wd 11]

Excellent work.  

[wicked 103 3 Cars]

Nice build!!

Don't be tempted to go mad on boost; the manifolds are known to crack; rather swap the cams for something better or so. 

The VAT25 is joy to drive; no turbo gap at all... 

 

[20five_t 1 1 Cars]

That's good to hear that the VAT25 doesn't have much lag. I'm planning to use the car with the standard T16 set up for a while and see how it drives. I'll also leave the boost alone to start with.

 

No doubt I'll start to think about modifications in the future though. I've not seen much info on different cams being used in the XU10J4TE - any suggestions of what would work if keeping the VAT25.

[20five_t 1 1 Cars]

2.5 " SS exhaust has been fitted and dash 2 pro is being set up.

hopefully not too far away from an MOT.

[petert 586]

Standard Mi16/S16 cams are a good start, or my Stage 1 profile and std exh cam on wide centrelines.

[Telf 224 2 Cars]

nice work- can you remember where you got the carpet underlay from?

 

[20five_t 1 1 Cars]

The underlay was from a site called newtoncomm.co.uk

It was less than 50 quid so not bad.

[20five_t 1 1 Cars]

4 hours ago, petert said:

Standard Mi16/S16 cams are a good start, or my Stage 1 profile and std exh cam on wide centrelines.

thanks for the info -    What sort of power increase do you think the stage 1 (with mapping etc.) would make on an otherwise standard XU10J4TE?

 

 

 

[petert 586]

You'd have to ask members from the T16 forum who have done it, such as AlexN. I suggest 20hp is easily obtainable over the standard T16 cams, which are very mild.

[20five_t 1 1 Cars]

Sounds worth while.

I'll run it standard for a while and get some base line info. After a few months i'll probably look it to trying some different cams with it.

[20five_t 1 1 Cars]

The MOT was passed last week -  It's been a while since the last one in November 2013.

Hopefully I'll be picking it up tomorrow.

 

[20five_t 1 1 Cars]

So, I drove the car 50 miles back today - mainly down motorways, but also got to take it for a few miles on some decent roads.

 

Its still running in so I wasn’t thrashing it, but opened it up a couple of times. The engine is running standard and like mentioned above, the boost builds early from about 1800rpm. Overall I’m really impressed with the it, particularly for something that age and not tuned - decent power and very useable delivery. Traction seems generally fine with the quaife diff. 

 

gearbox is vts with 3.8 final drive. The gears are longer than a 1.9 gti and revs on the motorway are better 3300 rpm at 70. I think the engine would work well with an even longer box though. There’s more than enough low down torque for it to use longer gears.

 

The other observation is that the Bilstein group n dampers are fine for normal road driving. Not too firm which I feared they might be.

 

 

 

[Andy 105 1 Cars]

I bet you are really pleased. Great work and a cracking car 

[maxi 36 1 Cars]

Awesome work, well done!

[maxi 36 1 Cars]

How did things tuyn out with this project in the end? Pleased with the car and setup?  Im also looking to source one of these complete power plants at the moment for a restoration project. 

 

Cheers

Maxi