[engine_work] My 2.0 Turbo Project

[Discostu 6]

Ok, well i guess it all began in April last year when i bought a 205 GTi. June of that year i swapped the orignal 1.6 8v engine for a 1.9 16v Mi16 from a 405, i wont bore u with the details of that project as its been done a million times before.

 

All was well with that until February of this year when it decided to self destruct

 

 

 

 

So a new engine was needed. Unsure for a week or two which route to take a 2.0 8v turbo from a Xantia Activa turned up (Thanks to Mikey G) for not alot of money. That was quickly snapped up

 

 

 

So out with the old (well, what was left of it lol)

 

 

Not taking any chances second time around the new engine was totally stripped and rebuilt. A few pics from various stages:

 

Whilst the block was bare i took the chance to GUNK it and give it a lick of black engine enamel:

 

 

Back in go the pistons, rods and crankshaft:

 

 

 

Now the head and block are re-united it can be timed up:

 

 

It begins looks like an engine again:

 

 

 

Bolting the turbo back on:

 

 

After reading most of the suggestions on here i decided to replace the 1.6 box i had been using with the Mi16 for a 1.9, these seam to suit the characteristics of the turbo engine better by keeping the revs down and the car on boost. After a quick swap with a friend i had the box i wanted, just to be sure i took it to the local gearbox centre and had them strip, expect and rebuild it:

 

 

With the gearbox back and fitted to the engine , all was fitted into the car:

 

 

But it was a VERY VERY tight fit, some modifications would need to be made!!

 

Space between turbo and brake servo:

 

 

Space between downpipe and bulkhead:

 

 

So.... the lower engine mount was cut and welded with an increased length of 20mm. By pushing the engine forward at the bottom it tilted it downwards at the back, giving valuable millimteres of extra clearance. Combined with a brake servo from an XS i now had lots of room to play with

 

 

Whilst checking clearances the gear linkages needed to be modified to clear the turbo. The 'L' linkage that controls forward to rearward movement of the gear lever was re-drilled, cut and bent. Not only did it clear the turbo, but with my adjustable linkage rods i now had a gear selection that was nice and tight

 

 

Even in its finished form it is very tight down the back. So with safety in mind i have heat wrapped all the fuel lines and oil/water pipes that run near the turbo and the exhaust downpipe (no pics of this):

 

 

Next up i decided to look at the airfilter and boost pipes to and from the turbo. The main boost cross over-pipe that i had sent off for powder coating returned looking better than i'd have imagined, painted an unusual silver/black speckle combo (not my idea but it does look great in the flesh), so that was fitted:

 

 

 

After looking at the route of the standard Xantia turbo inlet pipework it was obvious that it would foul the master cylinder and would not fit. But i wanted to try and retain the intended position of the filter, afterall its in a nice cool position as far away from the turbo as can be. So i bought some 'bling' alloy tubing and set about making up my own pipework (thankfully i have an auto bonet with the bulge, otherwise it would never have gone in):

 

 

 

Not too much left to do now then. Although i had a busy few weeks ahead getting the rest of the bits ready to be fitted:

 

Inlet manifold totally stripped and cleaned inside & out:

 

 

 

Most of the wiring was installed and the ECU trial fitted (later to be bolted down on the battery tray using a custom made tray):

 

 

New alternator fitted using a custom made mount:

 

 

 

New, smaller fuel filter fitted into the O/S front wing:

 

 

Next up involved alot of grinding. The standard sump had extra 'wings' front and rear to bolt to the larger gearbox the Xantia had, these were not required anymore and in fact fouled against my intended radiator location. Off came the front 'wing' and a lick of paint applied:

 

 

I also fitted a new starter motor whilst it was easily accessible:

 

 

On went the inlet manifold:

 

 

Next up i needed to figure out a suitable radiator, intercooler, oil cooler combination for the front. I eventually bought a custom made alloy intercooler, an alloy radiator and fitted the Mocal oil cooler i had alrerady used on the Mi16:

 

Whilst welding the brackets for the intercooler i also modified the front panel slightly to clear the boost hoses and made new brackets for the radiator to drop into (The fan cowling held it in originally but i was no longer using this) and had the entire front panel rust treated and re-painted:

 

Brackets for intercooler:

 

 

Front panel cut and welded:

 

 

Respray:

 

 

On went the intercooler:

 

 

Next up i fitted my new 11" slimline fan, this was fitted to the rear of the radiator and would suck. Not enough room for a blow in front. Then the radiator (a new alloy item i had purchased, much lighter than a standrad rad) was fitted and plumbed in:

 

The fan:

 

 

 

With the fan shrouding no longer supporting the weight of the slam panel it proved difficult to close the bonnet as there was nothing to take the wait of the push needed to engage the latch as the panel would bend. This was sorted by fabricating 2 uprights, these go from the lower cross member to the slam panel. They also proved very usefull for securing the radiator and oil cooler:

 

 

With the radiator and intercooler in position i could finally sort my boost pipes. The idea being to keep the route as short as possible to keep lag to a minimum. I purchased some stainless steel pipe that was pre-bent, cut them and then welded them to form an S bend that would clear the top of the radiator (no oil cooler in this pic but it does fit in there, sumhow lol):

 

 

 

The car was almost complete now. Just a case of removing the brackets i had made for powdercoating i could fully re-assemble the rest of the car. I obviously had to modify my front bumoer to accept the intercooler without sacrficing airflow. However i didnt want to advertise the car as being a turbo, this is the best i could manage:

 

 

Well i guess thats it for now. Still a few things i need to do to get it exactly how i want it, but i'm very happy with the results

 

At the moment, the car is running standard boost i would expect about 160bhp and 180lb/ft torque (estimates) it seams to pull very well and is completely different to the Mi16, it will take some getting used to thats for sure. I hope to suprise a few unexpecting people in her

 

Here are a few more completed pics:

 

 

 

And just to confuse and suprise people i put the old GTi badge back on:

 

 

Here is a short video of the engine running and boosting, it was not at its completed stage at this point:

 

http://smg.photobucket.com/albums/v642/dis...rrent=turbo.flv

 

 

I hope u enjoyed reading, all comments and suggestions welcome. I can take constructive criticism lol

 

 

I'd like to thank the following people for helping me during the conversion: a MASSIVE thankyou goes to Mikey G - for everything, couldn't have done it wihtout you!!! Tombo - for lending a hand, Matt - for the use of his welder, Kriss Aspinall - for the powder coating, Rob - for the gearbox and anyone else i'v forgotten

[Jrod 7]

Looking very good!

[Jer309GTi 3]

Wow, very impressive. Nice work!

[inferno 1]

very nice... almost makes me want to carry on with mine...

[Discostu 6]

very nice... almost makes me want to carry on with mine...

 

Almost? Stop slacking and get back to work... well worth the effort

[t16ryan 1]

Looking nice, nice quaility work how long did it take from start to finish?

[Discostu 6]

The Mi went pop on Feb 18th, finished this conversion last week so approx 3 months. We worked most weekends and nights on it

[Casanova 0]

Mmmm, engine porn... Looking gorgeous, lovely job

 

§

[tombo 0]

awsome job mate, i know all the hardwork thats gone into this car,and the outcome is more than deserved.

 

nice to know ive got my hands dirty on this and been a part of lending a helping hand. car is truly impressive.

 

but.... i will be honest the pics may look good but in the flesh this car is something else. stunning. and the sound now thats better than jenna jameson on orgasm!

[Powers 13]

Awesome mate. That engine bay and the attention to detail make that one of the neatest installs i have seen.

Hope to see it in the flesh sometime soon!

[M@tt 77]

Mate that is a fantasic job you should be very proud!!!

 

That's inspired me to get on with rebuidlignt he xm lump to go in my CTI

[sonofsam 5]

Look's awesome, congrats to all involved. Top job!

 

Aye, they do sound and go very well

[Mikey S 29 1 Cars]

congrats chap, looks a very neat and tidy install, i bet your well happy!

 

the more of these that spring up, the more it gives me incentive to get mine done.

[Spiky 37]

not bad, not bad at all

 

 

will be interesting around track when we battling

 

always looks so clean...lol top work dude

[johnrobertgordon 0]

That is bloody amazing. Fits together fantastic. Well done, Love the intercooler and positioning.

[Mikey G 3]

This thing has been the vain of my life for a number of weekends and evenings

 

I just need the keys for it now

[tombo 0]

mwahahaha mike i will be right behind you in the que to be a driver lol hahaha.

 

its a lively little so and so. mike why you lie for this has never been a vain, youve loved every second of it all them long hours and slaving and sweating over the thing.

 

[Discostu 6]

There was no sweat Tom...... just blood

 

Thanx for all the positive coments everyone, makes me happy to know its appreciated by fellow 205 owners

 

I will keep the thread upto date as and when i change things

[ChrisG 0]

Thats excellent mate

 

Obviously a lot of hard work and lateral thinking has gone in to it to make the finished product as good as it is

 

Good work dude!

[Alastairh 47]

Looks really smart!

[Drew O 0]

went for a quick spin earlier in this, was amazing carporn.com i only went for bout a minute but well worth it and the chatter ooooh it is just better than porn love this 205 great work all involved mine next lol

[johnrobertgordon 0]

Yup, I got to admit, its the sound of a turbo that makes it all worth while. I used to drive through town with a heavy right foot pulling away from a standstill in 2nd gear just to induce the compressor surge. I loved watching the young lads looking for some turbo'd mad house of a car but just seeing my tatty old 205........confused young faces a plenty. (bit sad I know but made me smile.)

[johno_78 2]

very nice job.

 

i've just bought a xantia turbo, that i'm running about in, and was gonna do a quick transplant.

 

After seeing this looking so good, thank you for the blood sweat and tears i'm gonna spend doing mine now.

[boeseturbo 1]

what intercooler did you use?

 

Looks really great!

 

 

Cheers

[Malachy 0]

This thing has been the vain of my life for a number of weekends and evenings

why does it keep making you look at yourself in the mirror?

 

i think you mean bane, not vain

 

with regards to the 205 very nice i like the rad/ic install looks very neat and is often one of the most trouble some parts of the conversionl.

regards

Andy

Edited June 11, 2007 by Malachy