[engine_work] Operation Turbo

[Discostu 6]

Managed to get mine in today aswell :blink:

 

 

Did u find it a very tight fit? I have almost no room between the servo and turbo?

 

 

 

Gonna have to extend the bottom engine mount a good 20mm to get it to clear.

 

I'm using a 1.9 box on mine. Unsure if i'm gonna need to use the GTi starter motor or the one from the Xantia?

[inferno 1]

the xantia starter will be a better slimmer one. nice looking bays there too!

 

ditch the 1.6 box as soon as u find a good working 1.9 or td box. the engine feels lazy like the 1.9gti and really doesnt suit a 1.6 box. ive fitted a known good 205 stdt box.

 

ive got another be3 derv box from a 305 van if anyone needs one? was tempted to keep it as a spare though tbh so didnt advertise it.

 

re the space between servo and turbo, there are some slightly smaller servos available, my 309 i fitted with one from a desel 205. my current conversion has a bias box.

Edited March 24, 2007 by inferno

[Discostu 6]

re the space between servo and turbo, there are some slightly smaller servos available, my 309 i fitted with one from a desel 205. my current conversion has a bias box.

 

Dont really want to go as drastic as a new pedal box. Do u have any idea if the servo from a diesel 205/xs/1.1 etc is any smaller than a standard gti?

 

Thanx, a little worried about clearance here

[max0 5]

Dont really want to go as drastic as a new pedal box. Do u have any idea if the servo from a diesel 205/xs/1.1 etc is any smaller than a standard gti?

 

Thanx, a little worried about clearance here

 

Hi mate nice looking engine I havnt got the turbo on yet as had the head off to get refaced etc after puting a new head gasket on

.

Im sure ive read about it tho... ill see if i can find anything.

[Mikey S 29 1 Cars]

Dont really want to go as drastic as a new pedal box. Do u have any idea if the servo from a diesel 205/xs/1.1 etc is any smaller than a standard gti?

 

Thanx, a little worried about clearance here

 

servo's from the lower spec models are smaller.

 

its interesting that you have no clearance there, on mine it misses it by a good inch and a half but the heatshield smacks the steering knuckle at the bottom of the column like a good un.

[Discostu 6]

Yet my heat shield is clear of the column

 

Wonder if its something to do with the year of the engines or the top mount used.

 

Mine is from a 98 Xantia activa, and is fitted with the top mount from a 306 gti-6

 

Interesting about the servo tho, i will have to look into it further

 

edit - sorry for spoiling u'r thread with all these Q's Max

Edited March 25, 2007 by Discostu

[Alastairh 47]

Looks a great project. i Agree with pugger though on the 1.6 box though.

 

A freind put a td box on his TT and that worked well

Edited March 25, 2007 by Alastairh

[205turbo 32 2 Cars]

have to agree a td gearbox suits the turbo engine, looks a great project

[jim21070 2]

Going on the power characteristics, a Diesel Box should be a fine match.

 

Anyone ever thought of using the ML5T 'box used in the Activa and 2.1TD models?

 

Or is the hydraulic clutch and cable-operated gearchange not feasible in a 205?

[Mikey S 29 1 Cars]

Going on the power characteristics, a Diesel Box should be a fine match.

 

Anyone ever thought of using the ML5T 'box used in the Activa and 2.1TD models?

 

Or is the hydraulic clutch and cable-operated gearchange not feasible in a 205?

 

i was thinking of using the me5t that came with my xm but when i did a search on it, the general consensus was that it didnt fit in the hole (oooeeerrr! )

Edited March 25, 2007 by pugger

[max0 5]

anyone know if you can use a lower strut brace with the turbo lump?

[rex 1]

"anyone know if you can use a lower strut brace with the turbo lump?"

 

I'm planning to use mine (OMP) - I'm already using the alloy sump with it on the 1.9...

 

Anyway, let me know how the 1.6 box goes - I have a TD box and think I'll go that route as there's nothing I hate more than wheelspin when you don't want it...

 

Cheers, Rex

[max0 5]

update! so much for the quick turnaround, anyway here are few more pics.

 

Got the cossy intercooler fitted at the bottom so havnt had to lower the rad etc. Looks quite nice but is quite close to the floor. Got a oil catch tank coming in the post.

 

Thinkin of adding another fan just in case.

 

Need to get some samco pipes etc so if anyone has any spare let me know after 63mm / 2.5 dia

 

The lower strut brace fits fine, cheers dan for the hand at the weekend!

 

Starting to take shape.

[max0 5]

few more pics shocks where fitted ages ago and so where the wheels with new f1's but thought id start a whole thread about my car and its progress.

[max0 5]

tonights fun and games - cutting the front bumper to allow air to reach the intercooler.

 

The picture looks a little ruff but ive used ms paint to show how im going to finish it tomorrow. I pratted about cutting less of the bumper and making it look nice to find it still was in the way and blocking air to the ic.

 

If anyone can think of different lines to cut tomorrow let me know

 

Andy

Edited May 8, 2007 by max0

[frodo_monkey 0]

Some good work there fella, have a well-deserved beer

 

Those lines look fine to me, but as you well know from having seen mine, I'm no perfectionist when it comes to looks...

 

Just don't go over any speed bumps - you saw the problem I had getting mine onto a trailer!

[Mikey S 29 1 Cars]

tonights fun and games - cutting the front bumper to allow air to reach the intercooler.

 

The picture looks a little ruff but ive used ms paint to show how im going to finish it tomorrow. I pratted about cutting less of the bumper and making it look nice to find it still was in the way and blocking air to the ic.

 

If anyone can think of different lines to cut tomorrow let me know

 

Andy

 

 

i like where that intercooler is maxo. how low is yours? whats the ground clearance like?

[sonofsam 5]

Looking good max0, here's Fuqa's mounted intercooler I was telling you about http://forum.205gtidrivers.com/index.php?s...=59446&st=0

 

Didnt know if you had found it or not, may help you with your pipework

[max0 5]

Looking good max0, here's Fuqa's mounted intercooler I was telling you about http://forum.205gtidrivers.com/index.php?s...=59446&st=0

 

Didnt know if you had found it or not, may help you with your pipework

 

 

The clearance is quite low tbh, I can move the intercool slightly (maybe half a cm up) but if needs be I can alter the height on the front shocks as its slammed at the moment. The picture was taken on a hill as well which i dont think helps. Snow / Rabbits / Road kill / Speed humps may be a issue :S

 

Cheers for the link sam will have to order some hoses tonight and start planning on connecting it all up

 

Si - think ive had too many beers - hense why its takin so long

 

Anyways ive got the bug again and its full steam ahead

[TEKNOPUG 3]

Looking good - personally I would have dropped the rad and mounted the IC above - but it'll work just the same. With regards to the gearbox - have you considered a hybrid option? On mine I run the standard 1.9 but with a TD final drive. That way I keep the 1.9 spacing (long 1&2, close 3/4/5) but just drag them all out by 10%. Works a treat.

[max0 5]

Looking good - personally I would have dropped the rad and mounted the IC above - but it'll work just the same. With regards to the gearbox - have you considered a hybrid option? On mine I run the standard 1.9 but with a TD final drive. That way I keep the 1.9 spacing (long 1&2, close 3/4/5) but just drag them all out by 10%. Works a treat.

 

I had planned on dropping the rad and mounting the IC above, however when it came to it I found it easyer and involved less cutting of the car! to mount the cooler below.

 

Yeah thought about the gearbox but its not important untill its up and running which is higher up the list of jobs How easy/hard is it to change gears over as ive never opened a gearbox up before.

 

Andy

[TEKNOPUG 3]

Dunno I got uncle Miles to do mine when he rebuilt it

[max0 5]

update - few parts arrived last week, oil catch tank and some new brake disks. now skint! ..

.. anyway with the added weight of the iron lump id like to go to gti6 brakes/309 drive shafts etc but funds dont allow at the moment so ive just gone for some cheap drilled / groved 1.6 disks which should work well along with the mintex pads.

 

Ill update the thread later in the week with more progress its not far off now. just really needs the wiring and hoses connecting up.

 

Andy

[smckeown 1]

Im willing to take the risk and see how it goes with the 1.6 box. Id rather fit a known good 1.6 box than shell out for a 1.9/td box to find its duff. It can be changed at a later date if needed.

 

According to Seans gear box excel file Seans Excel file there is only 1.3mph per 1000rpm between the first gear on a 1.6 box and a 1.9 box so i dont think the tyers are going to explode

 

it's the 1.6's higher final drive not the ratios that makes the difference, and makes it unsuitable for a turbo with oodles of torque

[max0 5]

*update* this morning she coughed into life on the first turn on the key. (once we worked out the wiring) Happy days Cheers jim for pinning out the ecu and all the help