My 205 Cti Turbo

[Jakob 1]

Some data and pics of my 205 turbo conversion.....

 

Peugeot 205 CTI

Mi16 blok and crank

XU10J2 2.0 8v top with 272 cam (I have a ported XU10J2 top to be installed later)

Adjustable camwheel

Turbo Technics original turbomanifold og piping

60:2 flywheel

Oil and intercooler

Garrett GT2860 RS (ballbearing)

OMEX500 management system (with premade wiring harness for the XU engine)

3 bar mapsensor

306 GTI (6) gearbox

Sachs clutch

309 front bumber

205 automatic bonet

Adjustable fuelpressure valve

Valve for adjusting the boost (manual)

Blow off valve open

 

You can see the intercooler in the front.

http://img177.echo.cx/img177/7527/front6fp.jpg

 

http://img218.echo.cx/img218/6351/16ke.gif

 

All the wiring harnes for the management system, starter, light, fans etc, was changed or fixed.

http://img218.echo.cx/img218/5950/38bx.gif

 

Sligtly modified original 205 GTI inlet manifold to match the XU10J2 8v top oval inlet holes.

http://img218.echo.cx/img218/7008/42dn.gif

 

The XU10J2 top (a ported top is on its way)

http://img218.echo.cx/img218/1917/61ss.gif

 

Allmost assembled - this is the latest pic I have.

http://img44.echo.cx/img44/9297/motor40nw.jpg

 

I will get some update pictures soon.

 

The engine was started for the first time this weekend. It didnt run very well in idle due to the startup map. I changed the map to another one and now it is running smoothly but with a very high idle of appr. 3000 rpm. This will be corrected when I will have the time to map the omex. However it is nice to hear and se the engine running fine and smoothly after 1½ year in the garage.

 

 

/Jakob

Edited October 27, 2005 by cybernck

[ablister 31]

that is very nice! I take it the orginal coolant expansion tank was too big. What one are you using? I'd maybe get a top cam cover as there are alot of hoses that are very close to that cam pulley!

[Alastairh 47]

Nice install.

[Miles 331 1 Cars]

looking good, Like the VW expansion bottle

[tom_m 0]

SWEET! looking good man! me likes!

[SamGTi 0]

Very clean and tidy! And probably got plenty of power to match I would imagine!

[boeseturbo 1]

How much HP do you running or do you plan to run?

Edited October 27, 2005 by boeseturbo

[RobMGti 0]

Very nice I cant see that being slow.

[jochem 0]

Looks great, well done!

 

I think the 6box would be a bit short for a turbo?

[mak 0]

tasty, how much boost are you going to be running?

 

How good is air flow to the air filter?

[miamistu 1]

Nice

 

Is that the final position for the coil pack?

[Guest andy309goodwood]

VERY NICE

how much modifiying was needed to match the inlet ports up

[Jakob 1]

  ablister said:

that is very nice! I take it the orginal coolant expansion tank was too big. What one are you using? I'd maybe get a top cam cover as there are alot of hoses that are very close to that cam pulley!

 

Yes, there was no space for the original expansion tank, so I got a smal one from a VW car. I do not know which one it fits original. I also bought the wiring plug to fit to my wiring harnes.

 

I dont want a top cam cover. The picture dosnt show the distance between the hoses etc. very well. They are all tiered up with a reasonable distance so there should be no problem

 

  boeseturbo said:

How much HP do you running or do you plan to run?

 

Actualy I dont know how many hp it will deliver, but I think it would be somewhere above 200. I will have to wait and see when I have mapped the omex. I will use a AEM wide band sensor to look for the AFR.

 

With the ported XU10J2 top and a bigger size throttle (Ø63) (now original 205 GTI) I hope to get around 250 maybe a little more. But again I dont know before it has been mapped. I will start with about 0,8-0,9 in boost. I also have my doubt about the TT exhaust manifold - if anyone know of high hp achived with this manifold I would like to know.

 

 

 

  jochem said:

Looks great, well done!

 

I think the 6box would be a bit short for a turbo?

 

Yes, it might be, but I like the short gear boxes as found in the 1,6 GTI (looking for the accelration). It may be to short but I will try it

 

  mak said:

tasty, how much boost are you going to be running?

 

How good is air flow to the air filter?

0.8 - 0.9 maybe more depending on the parameters, knock etc.

 

I am not sure what you mean by the air flow. It has 3' (Ø76) inlet piping to the turbo and a green "mushroom" filter placed down in the front at the end of the radiator pointing 45 degrees downwards.

 

 

  miamistu said:

Nice

 

Is that the final position for the coil pack?

 

It should have been. I made a stainless steel plade for it to mounted on. However I found an original XU10J2 coil pack that fits on the site of the top. So that is where it is sitting now. I will shoot som pictures when I get my camera back.

 

 

  andy309goodwood said:

VERY NICE

how much modifiying was needed to match the inlet ports up

 

Not much. I used my Dremel tool and to remove the material. It is not a 100% match and can never be, but now the inlet manifold ports fits where it is round. The inlet ports at the top will still have some edges and walls the air will hit before entering. And the angle of the manifold differ from the entering angle in the XU10J2 top.

 

My plan is to make a completely new inlet manifold from the XU10J2 manifold found on the 605 engine. This one has the runners made in aluminum and not plastic. It gives the oppertunity to cut it in halv and weld a custom plenum champer on it. But this will be a winter project if it will be neccesary.

[base-1 17]

Looks lovely

[TB_205GTI 1]

Looking really good Jakob. I like the 309 front bumper with the black car.

 

 

And oh nice to see you went for the GTI manifold and not the original 2.0 one you talked about

 

why didn't you go megaSquirt? carstens old 205 GTI-Turbo is now running MS, and it's soo smooth

[Jakob 1]

  TB_205GTI said:

Looking really good Jakob. I like the 309 front bumper with the black car.

And oh nice to see you went for the GTI manifold and not the original 2.0 one you talked about

 

why didn't you go megaSquirt? carstens old 205 GTI-Turbo is now running MS, and it's soo smooth

 

Hi Peter

For me it seemed more easy to go with OMEX as a turn key product and I got the unit with full wiring harnes for my engine - plus a MI-16 startup map with cps in place (60:2). However I may at some time try the MS when I have the time to read an get more in to the setup, advantages etc.

Do you know whether there has been any gains after the MS installment? I remember something about 170 hp before at 0.6 or so in boost...

 

-----------

 

Found some more pics..

 

This is how the first turbo looked like (T25 A/R 0.48 on compressor)

 

Then I went for at Ballbearing GT25 (There are two versions this is with the small compressor trim).

It couldnt fit in though as it hit the chassie wall to the cabine.

 

From the other side.. I finally went for the ballbearing GT2760RS - not on the picture

It is smaller in size but actualy has the ability of more power.

 

Engine before - what a mes!

 

Engine swap - old engine. 150 hp (portet top + 272 kent cam) 150.000 km. Gone and sold.

 

Engine swap - new engine

 

From other angles - with the GT2860RS mounted.

 

[mak 0]

as normally comes up in 'how much power' turbo posts, the tt manifold hasnt stopped saveloy hitting over 200bhp

[Jakob 1]

  mak said:

as normally comes up in 'how much power' turbo posts, the tt manifold hasnt stopped saveloy hitting over 200bhp

 

I am a littlebit worrid that the pressure will go back in cyllinder 2+3. It should be fine for 200-220 hp, but has anyone done 250 hp or more?

[Guest andy309goodwood]

not yet but im hoping to

the plan at the mo is to run a 2.0 bottem and mi16 crank and a bigvalve flowed 1.9 head and inlet manifold with ms ecu controling dis ign fuel and boost with a hybrid t25 from an sx200

ill also berunning a charge cooler and a much shorter inlet tract with a T/T manifold

im aiming for between 230 and 250 on about .8 bar

but its all theory at the mo but not for long as the 2.0t lump should turn up next week hope fully the games will begine

Edited October 28, 2005 by andy309goodwood

[Jakob 1]

  andy309goodwood said:

not yet but im hoping to

the plan at the mo is to run a 2.0 bottem and mi16 crank and a bigvalve flowed 1.9 head and inlet manifold with ms ecu controling dis ign fuel and boost with a hybrid t25 from an sx200

ill also berunning a charge cooler and a much shorter inlet tract with a T/T manifold

im aiming for between 230 and 250 on about .8 bar

but its all theory at the mo but not for long as the 2.0t lump should turn up next week hope fully the games will begine

 

That is more or less what I am hoping for. Do you have picture of the shorter inlet tract manifold?

[TEKNOPUG 3]

The was a guy over on Aussiefrogs.com who had an 8v with a T3 and chargecooler running 300bhp - ish. I'll see if I can find it for you.

 

here you go: http://www.aussiefrogs.com/forum/showthrea...64&highlight=T3

[keith 0]

300hp out of an 8v is nuts! fair play

[tom_m 0]

nuts it might be, but fun it sounds!

Edited October 28, 2005 by tom_m

[TB_205GTI 1]

  Jakob said:

Hi Peter

For me it seemed more easy to go with OMEX as a turn key product and I got the unit with full wiring harnes for my engine - plus a MI-16 startup map with cps in place (60:2). However I may at some time try the MS when I have the time to read an get more in to the setup, advantages etc.

Do you know whether there has been any gains after the MS installment? I remember something about 170 hp before at 0.6 or so in boost...

 

They haven't had it on the rollers yet, but they gave it a bit more boost, so it's above 170Bhp now I do not know how much yet, but close to 200 I guess.

[Jakob 1]

  TEKNOPUG said:

The was a guy over on Aussiefrogs.com who had an 8v with a T3 and chargecooler running 300bhp - ish. I'll see if I can find it for you.

 

here you go: http://www.aussiefrogs.com/forum/showthrea...64&highlight=T3

 

Thank you very much for the link

I havnt found many 205 turbo conversions on the net. It seems like this one made a quite nice exhaust manifold, which may give a higher output.