[engine_work] 306 Project

[Rob Turbo 3]

A few months ago I bought a 306 1.4 XN, I bought it as a cheap car with every intention of keeping it standard and cheap to run! But, after just a few days I'd decided to change a couple of things, just the stereo so I could play cds and some alloys, I went for a kenwood cd player, 2nd hand off a mate, and some cyclone alloys, that would be all I thought!

 

Until I saw some ph2 lights and thought they looked better than my ph1 jobbies! So then I had this

 

 

Mount everest anyone? The ride height just wouldn't do so I invested in a gti6 rear beam

 

 

To sort the front I got some xsi shocks and springs and chopped the springs as a short term solution (with the 1.4 being sooo light the xsi springs raised the front as standard!). The lad I got the shocks and springs also had a complete front end from an xsi going cheap and that gave me an idea, convert to an xsi engine! So I bought the subframe, hubs and driveshafts off him, then got to thinking about my old 205 turbo, and decided it would be about the same ammount of work to go turbo, it would be rude not to!

 

So I sourced myself a 2.0 8v turbo lump, stripped it down and cleaned it up a bit, changed the valve stem oil seals then bolted it all back together

 

 

 

 

 

I didn't get any wiring with the engine, but I already had a 2.0 8v turbo ecu and an s16 wiring loom so I set about modifying the loom

 

 

 

I went for a gearbox from a 306 TD that I got off a mate for £25, just need a clutch now. While I was at it I rebuilt the turbo so shouldn't have any problems with it any time soon! With my 205 turbo I had fueling problems, on the RR graph I have you can see the power drop off suddenly so this time around I've gone for an adjustable FPR, I've been buying a few bits from on here and ebay to have everything together before I pull the car to bits, I'm hoping for just a weekend off the road when it comes to the conversion!

 

In the meantime I've been altering the car again! I fitted a momo sterring wheel and made a boost gauge holder out of an air vent

 

 

Bought some morettes and made a badgeless grill

 

 

That was before I fitted the grill, the missing headlight is a cold air feed, I did this because the lamp was smashed when I got them (got them cheap though!) it's now got mesh over the hole and a 205 gti air box behind the light with a pipe going to the hole.

 

I've also now got a sport bumper on (as found on the dturbo, xsi and s16, not some chavvy thing), a peugeot sport spoiler and some half leather seats from a 306 meridian, and I've fitted some clocks from an s16 with blue led's in!

 

I'm working on a boost switch, so I can switch between 6psi (lowest I can go with the actuator) and either boost controlled by the ecu or through a boost controller set at whatever I feel like!! I bought a push button switch off ebay and I've modified the ash tray to put the button in so I can hide it! I still need some bits before I actually start the conversion, mainly pipes, both boost and coolant, I'm using the standard 2.0 8v turbo intercooler and radiator, the wiring still needs finishing, but I can't do that until I have a wiring plug to plug it into the car, I can either get one from a scrappy or wait until I take the car off the road for the conversion and chop it off the original loom.

 

Progress has slowed down a bit now due to waiting for parts to be delivered and it's getting too cold to work in the shed! Sorry for the length of this post but I started it a while ago so had quite a bit to fit into the first post! I'll go into a bit more depth with pictures in the right places as I go, I haven't been taking photos of the recent bits but will be taking some soon!

[24seven 104]

sounds like a good project mate, keep it up! I'm planning on an s/c conversion on my 306 XS.

[Rob Turbo 3]

Quick update, I've got a couple more pipes, just need the top rad hose and oil cooler to rad pipe from an xm (anyone got any left over from a 205 turbo conversion?) Got a clutch for a 306 td ready to go on, the boost button is mounted in what used to be the ash tray now, I finally got the tracking number for the xm pipes I paid for a couple of weeks ago although the parcel force website isn't much help, when I put the number in it says "Your item is being processed but we have not received confirmation of delivery." I could tell them it hasn't been delivered!!

 

I polished the rocker cover, mainly by hand with wet and dry, from 320 grit to 1500 then g3 polish, but my dad bought a polishing kit and it's like a mirror now, it's no good for the boost pipes because it has to be smooth and the pipes are cast, I'll just go through the wet and dry method until it's fairly smooth then get the polishing kit out and shine them up, you can get a restoration kit that can take stuff from very rough to ready for the polishing kit but that will have to wait with xmas coming up!

 

I've been offered a big tent type jobbie that will fit the car in so I can do the conversion on the concrete base in the field out the front of the house and still have some level of weather protection! I'm planning on starting the actual conversion on the saturday after I break up for xmas so I don't need to use the car for a while if anything doesn't go to plan.

 

I can't upload any photo's just yet, since my computer problems about a week ago I can't connect my phone to the computer, I'll have another crack at it at the weekend if I get time, I'm off to pug tomorrow with a list of bits that I need and I have to take the missus to argos to pick some stuff up that I'm not allowed to look at!!

 

Anyhoo, more to come soon! If anyone has already done this conversion I'd appriciate any tips you have to offer!

 

Thanks,

Rob

[sonofsam 5]

Hi Rob, cool project mate. You must have plenty room up front of your 306 to go with the original I/C.

Only person I know of on here who has a 2.0T in a 306 is malachy, maybe worth a PM for some tips.

 

I bought that 2.0T fitting guide of ebay a while back mainly out of interest as I'd finished mine, and the only thing

in that it mentions having to remove parts of the exhuast/turbo heatshield and maybe some bolts that hold it on

to stop any fouling on the brake servo and that the lower mount didnt need extending, however Im not

speeking from experience on that! Will be interesting to hear what you have to overcome with this conversion.

 

Sam.

[Rob Turbo 3]

The lad I got the engine off (not sure if he's on here or not, I know his mate is though!) had the same engine in a 306 and he told me there's a box section type jobbie that runs across the bulk head and that needs a bit chopping out of it above the steering knuckle where the rack meets the column, and that once he fitted it like that it was still very tight so he extended the lower mount as well, I had a quick look while I was there and it did look tight but I could hardly see behind the engine!

 

I'm going to try it for myself when it comes to fitting though, I'm hoping I don't need to extend the lower mount so everything stays at the right angle.

 

Before I decided on which radiator and intercooler to go for I went on ebay and looked at the brand new ones that have the measurements on the photos then measured the space at the front of the 306 and it seemed like it would fit nicely, but the lad I got the engine off was using standard 605 rad and intercooler and said it fits but you need to make the gap a bit wider, so again, I'm going to have to wait and see for myself how it goes!

[Hilgie 16 2 Cars]

All looking good!

 

Although I would use a 2.0T loom and not modify an S16 one...too much work and it will certainly not work (properly) due to missing sensor and other wiring.

 

You do know you have to cut away the frame on the bulkhead a bit to clear the turbo?

 

Cheers,

Hilgert

[Rob Turbo 3]

I don't have a 2.0T loom though or I would have used it, the s16 loom has everything the turbo loom had and more! It has 2 ignition amplifiers and a connection for 4 coils, I've moved all the plugs that need moving and changed the coil plugs to just one plug for the coil pack and removed the extra plug for the ignition amp.

 

I did think I had to cut away the frame on the bulkhead but wasn't 100% sure

 

Thanks,

Rob

[carbers205 1]

Rob I thought after all you said on the 306 forum this was going in the projects section not general chat! Lol.

Anyway, progress is looking good, amazing how quick these things can be stripped after a bit of practice!

I'm gonna mock up a WIP thread over on 306 once my engine is back together again tomorrow!

 

Andy

[Rob Turbo 3]

You can't post in the projects section on here, it has to be moved there by a mod if it is deemed suitable, I think I'll be keeping away from the 306 forum, it's dropping to bits and badly run!!

[carbers205 1]

Ah right, didn't know that, my apologies!

Was that badly run as in they haven't taken you up on your suggestion yet?! Lol.

No I know what you mean though, like I said the other day the technical know-how on here is much greater which is why I'm still floating around!

Will be interesting to see how well this machine goes once its all up and running!

[Rob Turbo 3]

Well I got my phone connected to the pc at last, all that wait for 2 not so good photos!!

 

Here's the shiny rocker cover, the photo really doesn't do it justice!

 

 

It's fitted now and shows the rest of the engine up, but at the end of the day it doesn't matter what it looks like as long as it goes like stink!!

 

And here's the boost button in the ex-ashtray!

 

 

That button will be connected to an escort RST boost control solenoid to switch between 6 and 14psi! Also, the rest of the pipes turned up, but some are missing so I've decided to get a back up plan, namely a cossie intercooler and some random ally pipes, so either way I should be able to slot something together! I got myself to pug today to order some odds and ends that should be with me on wednesday.

 

If anyone reading this is going to be doing a turbo conversion and not using the standard intercooler or pipes I'll take the pipes off you, the 2 I'm after are the boost pipes from either end of the intercooler (one to throttle body and the other to the ally/plastic pipe from the turbo) I'm not bothered what setup they are from, I have both 406 type boost pipes and xm type!

 

That's all for now folks!

 

Rob

[danpug 1]

Can those solenoids be wired into any turbo conversion? i might be doing a conversion running a dta, would it work on that sort of setup?

[All Praise The GTI 3]

hello mate can i ask where you got the pod that the boost gauge sits in or did you make? and how please?

also how did you block off the vent?

id like to put my boost gauge in my dturbo there but was not sure how to. at the mo its wedged in the small compartment in lower center console

[Rob Turbo 3]

@danpug,

 

You can use that solenoid in any turbo yes, the pipe that goes to the actuator needs to be cut and you put the solenoid in so that when it's off it goes straight to the actuator and when it's on it goes through a boost control device of your choice then to the actuator, so when it's off you have standard boost, when it's on you get whatever you set the controler at!

 

@All Praise The GTI,

 

I made the holder myself from the old vent, a quick guide for you!!

 

First, pop out the vent and disconect the plastic pipe, take the pipe off completely, there should be 2 bits of pipe, take the flexi bit that connects the blower thing in the middle of the dash to the vent and block it up with expanding foam then put it back on. On the back of the vent there is a bend that has a flap in it, cut the bend off and remove the flap, you can just un clip the bend but then you will be left with a hole where the open/close roller thing goes. Unclip the vent from the housing to make it easier to work on.

 

Take your boost gauge (or whatever gauge you want!) and cover it in sticky tape the wrong way, so the non sticky bit is against the gauge so you can slide the gauge out, then hold the gauge against the vent and mark where the fins need cutting, then cut them away, keep trial fitting the gauge until it fits in nicely.

 

Then put the gauge in (still with sticky tape on) and fill the back of the vent with that pre-mixed fibreglass stuff, comes in a tin like body filler, make sure you get it all the way around the gauge but not too close to the front of the vent, once it's gone hard, slide the gauge out of the tape, you will probably be able to pull the tape off the fibreglass fairly easy.

 

Now just skim the front of the vent with body filler, sand it smooth then spray (I used peugeot black and it's not a match to the plastic, but it's black!!)

 

When I did mine I put it in at a bit of an angle towards the driver before I filled the back with fibreglass.

[All Praise The GTI 3]

awesome. cheers mate

[Rob Turbo 3]

I now have all the pipes I need and I've set about sorting the shafts, I've bought 2 outer cv boots and ordered 2 inner ones which I should be getting on monday, I also found that I need a wheel bearing in one of the hubs, it was fine when I got it but has been sat for ages and is now jammed so the bearing must have been on its way out anyway!

 

I've bought a wheel bearing kit and been fighting with the hub most of the day, finaly got the circlip out that holds the bearing in, after lots of swearing and hammering I gave up and got the oxy acetylene out and won!! I haven't got the bearing out yet, it's too cold in the shed. Tomorrow's task is to get the bearing out and get inner race off the hub, to make getting the inner race off (I'm sick of grinding them off!) I bought a bearing puller from machine mart and what a load of crap it really is!! I bent the blades on it the first time I tried to use it, so angle grinder it is! I should get a press as well, it's torture changing wheel bearings in a vice, there's a bloke down the road from me with a press that I can use whenever I want, but he's been away for a few days so I can't get the key!!

 

I picked up my portable garage yesterday as well, well, a big tent! Just a couple more bits to get and I'll be away, I keep forgetting bits that I need and I'm sure I'll come to do it and realise I don't have something really important!

 

Thanks to everyone that's been supplying me with various bits and bobs!

 

More to come soon!

 

Thanks,

Rob

[Rob Turbo 3]

Been busy again today!

 

I changed the head bolts for new ones, modified a coolant pipe from an s16 to fit, that goes from the water block behind the pump, across to the gearbox side, then a hose goes from there to the heater matrix, I've had to remove the turbo bracket to get it on so I'll be chopping the bracket down so it fits again. I've finished doing the wheel bearing, what a pain that was! Never had one that was so hard to do before. I also pulled one of the cv joints off to change the boots, I'll do the other one tomorrow when I have the rest of the boots.

 

I also got the plug lead tidy thing bolted back on!! I seem to spend most of my time looking at the engine thinking "what needs doing?"

 

I seem to be working on it all the time but nothing is actually happening!

[Rob Turbo 3]

I got the inner cv boots today, I originaly got them yesterday but they were the wrong ones, the part number in the catalog at the local motorfactors was wrong, one of the lads there said he'd had the same problem before and ordered some off an xm that are the right size, so I now have 4 shiny new cv boots on the shafts all ready to go on!

 

Been getting a bit of overtime in at work this week so should have some more spending money tomorrow (pay day!!) so that should get me a thermostat, clutch cable and ht leads with some spare cash for if I remember anything else!

 

Only about 2 weeks until I start it!!

[Rob Turbo 3]

Picked up the last couple of bits that I ordered from pug yesterday, I was going to be finishing off everything on the engine this weekend but it's started snowing so I don't really fancy playing in the shed just yet! Also my crankshaft sensor came the other day and the VSS for the gaerbox came this morning, it's the 3 pin type so I can do away with the "control box" which should make things easier, especially seeing as I don't have a control box for it!

 

I've been reading through a few of the 2.0 8v turbo conversion threads and it seems that I'll be getting some decent power from this engine, it turns out that my last turbo engine, that I had in the 205, was the 140bhp ish lump with flat pistons, this one has the dished pistons which I think makes it the 150bhp version, someone correct me if I'm wrong, as far as I can tell this is the only difference I can see between the engines, apart from small differences like where clips are and the type of top mount!

 

Thanks,

Rob

[sonofsam 5]

I have the RGX and it does make good power @ 0.65bar standard, never had the head off though to see wich type of piston are in there.

But I think you are right, not much difference in them. Doesnt the RGY have a lower C/R also ?

 

What gearbox you going for btw ?

[Rob Turbo 3]

I'm not sure on the C/R of the 2 engines, but I know that if you are planning a 16v conversion the RGY engine is the one to go for, the pistons clear the valves without modification!!

 

I'm using a 306 turbo diesel gearbox. The odd thing with my last turbo (in the 205), the XM that the engine came out of had a BE3 box fitted, I'm almost positive that this can't have been standard, it was an 'L' reg if that makes a difference? but that means that whoever changed the box must have changed the flywheel and clutch as well, so I don't know what clutch was in either, but after my 1.9 gti box went pop I fitted the box out of the xm, which appeared to have about the same ratios as a 1.6 gti box!!

 

The engine made around 120bhp at the wheels, which the bloke at the RR said was around 160bhp at the fly, and it was badly underfueling, I'm not sure why it was underfueling, seeing as another turbo conversion on this forum has made around 170-180bhp at the wheels with a standard engine bar exhaust, intercooler and air filter (which mine had also!)

[sonofsam 5]

I'm not sure on the C/R of the 2 engines, but I know that if you are planning a 16v conversion the RGY engine is the one to go for, the pistons clear the valves without modification!!

 

I'm using a 306 turbo diesel gearbox. The odd thing with my last turbo (in the 205), the XM that the engine came out of had a BE3 box fitted, I'm almost positive that this can't have been standard, it was an 'L' reg if that makes a difference? but that means that whoever changed the box must have changed the flywheel and clutch as well, so I don't know what clutch was in either, but after my 1.9 gti box went pop I fitted the box out of the xm, which appeared to have about the same ratios as a 1.6 gti box!!

 

The engine made around 120bhp at the wheels, which the bloke at the RR said was around 160bhp at the fly, and it was badly underfueling, I'm not sure why it was underfueling, seeing as another turbo conversion on this forum has made around 170-180bhp at the wheels with a standard engine bar exhaust, intercooler and air filter (which mine had also!)

 

Im considering a 306TD box myself, you'll have to let us know how it compares, ... very odd thing indeed you found there with that XM!

[Rob Turbo 3]

I've now got almost everything I need (and only 4 working days between now and the heart transplant!!), tomorrow I'm off to newcastle to get some 3" mandrel bends, a back box and a 3" rolled out exhaust tip so I can build the exhaust, at first I was going to measure the angle of the bends in the exhaust then order them, but it's been too cold or wet or I've been too busy to get out and do it so I've come up with a better plan! I'm going to get 2 U bends, this should be more than enough bent metal to build the exhaust and also cheaper than buying all the bends seperate!

 

Has anyone had any experience with pipe expanders such as THIS? (Sorry for the ebay link, I hope it's allowed in this section to aid explanations!) Will it expand 3" stainless pipe easily so I can make it slot together where I need it to or would I be better off buying flanges or taking the pipe to somewhere that can do it for me? I'll probably be buying a pipe expander anyway because my dad reakons it will come in handy (basically he wants one to make his "projects" easier!!)

 

The bits I'm missing are a timing belt cover, but I might have one sorted soon, and the coolant pipe from the oil cooler (heat exchanger) to the radiator, which might be getting donated by m@tt if he A: has one and B: doesn't need it for his conversion! If the worst comes to the worst I can get the pipe I need from pug for about £13, but that would mean a half hour journey (each way) after work on monday to order and pay for it, then the same journey again on wednesday or thursday to pick it up! They are spot on at my local (if you can call it that) pug dealer but I'm sick of going through for bits now, I must own half of pug by now!

 

It's getting close now and I'm sure that I'm going to have missed something and be left without a car for the whole of the holidays!

[sonofsam 5]

Link not working Rob, No experience with such expanders, however I do with sheet&tube metal @ work, as we use a power press/fly-press or swaging wheels

to do what you asking about, depending how thick the stainless is it may need some sort of heat treatment (annealing) to expand further!

But i can see what you are trying to acheive with this, much like the bends/lengths you get from Jetex that have a swaged end and slots for another pipe the

same dia. to slot into. and be clamped up. Wich is what I used on my exhuast and was very easy to assy. and was very cheap to build the whole exhaust too!

[danpug 1]

My local pug dealer posted a part (throttle cable) to me with no charge previously, it got lost in the post so they dropped it to my house by hand! A couple of days later the other cable turned up, oops! Perhaps ring them up and see if they will send it to you?