[car_upgrade] 2.0l Turbo Conversion With A Euro Rallye Flavour

[sonofsam 5]

Cheers, got it from here: http://www.velleman.be/ot/en/product/view/?id=9060 it is a kit, but luckily I didnt have to build lol

[sonofsam 5]

Well hello, thought a little update may be in order, seeing as Im still working hard on my project

You all know what it's like, you start just meaning to do one job ( popped a boost hose off down by the radiator) and it turns into a myriad of others, lol

So what ensued was, a full rework of all the coolant hoses, new oil filter, new boost regulator solenoid

and some extra cooling space upfront.

 

Big thanks to BBM for supplying the silicon coolant hoses

I managed to utilise :

Expansion tank>water block hose, with a tee off into heater matrix.

Top thermostat>radiator with a tri piece off to heat exchanger and turbo.

Just waiting on a mi16 lower heater matrix> side of thermostat hose to finish it all off.

Also brazed a union onto the bottom metal pipe for the other side of the heat exchanger,

make's for a much neater conversion, as I dont have so many hoses passing behind my boost pipes now.

 

Oil filter needed doing as I gave it a little knock when installing my engine the second time around.

reinstalled my electronic boost valve according to this topic, fingers crossed it all works well again.

 

So while half of the front of the car was out, thought I'd make a bigger hole

in the valance to aid air flow onto the intercooler, its a bit on the flimsy side now though!

Also installed one of my very own ducts, not operational yet, but I may look into producing

a hole in the inner wing to feed cold air upto the air filter.

 

After doing a little photoshop of the twin headlights on my car, I decided they were not for me,

so I sold them, for double what I paid

 

Thanks for reading and here's some pictures.

 

 

 

http://i23.photobucket.com/albums/b393/djs...am/DSC00151.jpg

http://i23.photobucket.com/albums/b393/djs...am/DSC00145.jpg

 

 

Sam.

[bales 1]

Whens this second video coming

 

And have you got the new eprom in yet?

[sonofsam 5]

To be honest, I have all these performance parts sitting in my garage! Better cam, bigger turbo

better manifold, but Im in no real rush to fit them

180 lb/ft of torque is proving very quick in the little 205 But yes chip soon mate, as soon

as I've tidied up the engine fusebox area

 

Had the tracking set again today and got them to check all the subframe bolts, was a few loose by all accounts Knew i could feel something not quite right, and really was not in the mood

to get underneath her today

What a difference it has made, spent all afternoon driving round(corners) absolutley it

 

Would love to crack on with the video mate, just waiting on some diodes to see if I can get my

digital dislpay tacho working and reinstall a speedo cable and figure out how to mount the camera!

Thinking of a bracket using the old seatbolt hole up on the B pillar, or I might just gaffa the camera

to the bonnet

[inferno 1]

mmm loving the new metel pipe on the inner wing! one think puzzling me though... where have you mounted the ecu? have u extended the loom?

[bales 1]

To be honest, I have all these performance parts sitting in my garage! Better cam, bigger turbo

better manifold, but Im in no real rush to fit them

180 lb/ft of torque is proving very quick in the little 205 But yes chip soon mate, as soon

as I've tidied up the engine fusebox area

 

Had the tracking set again today and got them to check all the subframe bolts, was a few loose by all accounts Knew i could feel something not quite right, and really was not in the mood

to get underneath her today

What a difference it has made, spent all afternoon driving round(corners) absolutley it

 

Would love to crack on with the video mate, just waiting on some diodes to see if I can get my

digital dislpay tacho working and reinstall a speedo cable and figure out how to mount the camera!

Thinking of a bracket using the old seatbolt hole up on the B pillar, or I might just gaffa the camera

to the bonnet

 

Well if you ever find yourself so pleased with your car that you don't fancy anymore power and want to sell any of your performance bits, you know where I am

[johnrobertgordon 0]

Hows yours coming along now bales? sorry to be off topic Sam.

 

John

[sonofsam 5]

mmm loving the new metel pipe on the inner wing! one think puzzling me though... where have you mounted the ecu? have u extended the loom?

 

That pipe causing me some greif at one point! tryed to weld stainless and mild to it using the correct

wire for each material, but it just would not seal. Although my welding skills leave a little to be disered

Brazing on a bit of mild steel pipe worked in the end though. ECU is over infront of the battery, only had

to extend one of the brown multiplugs to get it to reach.

 

Well if you ever find yourself so pleased with your car that you don't fancy anymore power and want to sell any of your performance bits, you know where I am

Get your own stash

 

 

Hows yours coming along now bales? sorry to be off topic Sam.

 

John

 

Thats OK mate, it is after all the same conversion

[bales 1]

Hows yours coming along now bales? sorry to be off topic Sam.

 

John

 

 

The engine is going in this coming week and as long as it all goes to plan (it worked in your car wiring wise so i am hoping it will in mine ) it should be getting started next week and hopefully back on the road in 2-3 weeks.

 

Then when I can drive it all the suspension etc....will be getting sorted but I just want to drive the bloody thing now!

 

Just as an off-topic did your heater work in your car John because with the plumbing you have on the engine I have no idea how you did it?

[johnrobertgordon 0]

yup, heater worked fine, I cant help you as to how it worked though, I did not fit it. I know they used a long metal pipe near there though.

[sonofsam 5]

bales, buy yourself a silicon Mi16 lower heater matrix>side of thermostat hose of StewBBM, it fits perfectly.

Then use the standard upper heater matrix outlet hose and tee that into the hose coming off the bottom

of the expansion tank.

 

Was that other hose you were enquiring about recently for this conversion?

If so, I used a 25mm I/D 90 degree bend to come from the lower metal pipe to join upto the side of the water distribution block

at the back of the engine.

 

Also worth checking you have a secure union from the metal>rubber pipe coming from the underside

of the turbo, as I've just fixed a leak at that point that had me worried about possible HG failure!

Using jubilee clips for such a small pipe diameter is not really a good idea Peugeot,lol

 

Hope it all goes to plan Man

Edited April 14, 2007 by sonofsam

[sonofsam 5]

Woot! Thread from the dead time, yes it's taken me this long to sort this out,lol.

Installed it yesterday after killing a few set's of clock backings and a few guages mounts too!

 

 

very pleased with how it's turned out, still to sort though is: Oil temp gauge wiring into turbo loom, box

of tricks for the tacho (being built by a freind for nowt:D and install a shift-light somewhere.

 

It's nice to have instrument lights again, and more importantly, a speedo!

 

 

Cheers all

Sam.

[Dan Ingram 1]

Have you got a seperate rev counter then?

[sonofsam 5]

No, its the digital display rev counter/tachometer you can see in the picture, in place of the the standard dial.

[Jrod 7]

Hows that work Sam, is it 2 number or lines etc?

[sonofsam 5]

Im guessing it's going to be two numbers, not actually wired it in yet!

Always got the BX dials if it falls through.

[willxs 0]

Looks awesome! also very sneaky! i like it.

[205turbo 32 2 Cars]

very nice,

 

like the boost guage, reminds me of matconys extra boost guage in his old TT

[TEKNOPUG 3]

Have you sacrificed the oil pressure gauge for a boost gauge?!

 

I think that I'd rather know if I've lost boost pressure than oil pressure....

[sonofsam 5]

Yes, the xu10 runs an oil pressure warning light only!

 

So, I think im bound to notice a big red light on the dash

rather than a gauge, wich is what im off to fit right now.

[Edp 67 3 Cars]

I'm loving that.

[Mikey S 29 1 Cars]

how did you get on with it sam? any photos mate?

[Sandy 191]

I did a similar thing in the Trio:

 

It's much easier with the 309 base model dash, because it's not back lit, so you don't have to cut through that weird brittle orange plastic! Also, the speedo cutout is easier to adapt.

[sonofsam 5]

My next mission (should I choose to accept it) is to remake those orange plastic bits out of

blue tint perspex

 

Got rained off fitting the oil light(have been moving house too!) But I have the tacho adaptor now,

so will wire it all in at the same time.

 

Cheers for the comments

[sonofsam 5]

Got rained off fitting the oil light(have been moving house too!) But I have the tacho adaptor now,

so will wire it all in at the same time.

 

That was a bit of a porky! I can't get to the coil pack plug and leads sufficently

enough to be able to tap into the wires without removing a boost pipe and possibley

a coolant hose

Here is the tacho adaptor though:

Give the guy his due, he's done a top job for no cash, hadn't expected it to be

this heavy duty though If anyone wants any diodes drop me a PM

 

Did manage to get the oil temp. gauge working and low pressure light installed:

 

And here is a completely gratuitous engine shot, after all the tidying and rerouting of stuff

 

However this week I have been mainly (as this is my daily driver now) removing all

the creaks, rattles and squeaks in the car and fitting some ICE

 

Next update will be the bodywork fo sure