Xm Turbo Conversion

[colti 5]

Hi folks.

Have aqquired a 1.6gti with an early XM turbo engine fitted.Will be rebuilding the car with to use soley as a track day Chariot.Its a tidy white 1990,stock only for the engine conversion that was done(somewhat badly) by a specialist who will remain nameless.

Have also picked up a scruffy ex track 88 1.9gti that has been relieved of its cage,bucket seats,pug challenge suspension,309 rear beam and 306 front brakes.

However,on inspection i find i have a lower spec RGY engine.Apparently its running slightly higher compression over the RGX motor at 8.5:1.The exaust manifold looks awfully restrictive!

180-200 brake would be good,But have i got the wrong motor?

[Rob Turbo 3]

Change the cam (a 1.9 gti DKZ seems to be a popular choice if you can find one, 306 2.0 8v xsi cam is next best thing I think), a decent intercooler and an adjustable fuel pressure regulator set up properly will see good gains. Also a decent exhaust system would be a good idea, I think 2 1/2" pipe is reccomended.

 

I had the same engine in my old 205, standard engine with a 4x4 sierra cosworth intercooler and 14psi of boost and made 160bhp (flywheel) on a rolling road, although it was running lean and would have done better had I have had an adjustable pressure regulator. I never got to try it becuase the turbo sized and instead of sorting it out I started a 16v turbo conversion that never got finished!!

 

I'm now doing another 8v turbo conversion in my 306 which should be making good power, it's a 150bhp engine to start with, with a bigger throttle body from an s16 and a 3" exhaust system to help it breathe and an adjustable fpr that should sort the fueling!

[whizzer71 0]

Change the cam (a 1.9 gti DKZ seems to be a popular choice if you can find one, 306 2.0 8v xsi cam is next best thing I think), a decent intercooler and an adjustable fuel pressure regulator set up properly will see good gains. Also a decent exhaust system would be a good idea, I think 2 1/2" pipe is reccomended.

 

I had the same engine in my old 205, standard engine with a 4x4 sierra cosworth intercooler and 14psi of boost and made 160bhp (flywheel) on a rolling road, although it was running lean and would have done better had I have had an adjustable pressure regulator. I never got to try it becuase the turbo sized and instead of sorting it out I started a 16v turbo conversion that never got finished!!

 

I'm now doing another 8v turbo conversion in my 306 which should be making good power, it's a 150bhp engine to start with, with a bigger throttle body from an s16 and a 3" exhaust system to help it breathe and an adjustable fpr that should sort the fueling!

 

 

Sorry to Hijack ,but just how much bigger is the S16 throttle butterfly over the std one and where can I get one ?

 

Cheers

 

Tris

 

[James_R 3]

You can knock the boost up with a Dawes device and will give you a good gain, I've got an Activa running 0.80 bar and it made 174bhp 200lbs. Although the std injectors are meant to only be good for 180bhp, so it's getting a bit boarderline there.

 

There's a chip available, sonofsam is doing it at the moment, and again a DKZ cam is a good mod (I've got one, just haven't fitted it yet)

 

I've got an s16 TB if someone has a use of it.

[whizzer71 0]

You can knock the boost up with a Dawes device and will give you a good gain, I've got an Activa running 0.80 bar and it made 174bhp 200lbs. Although the std injectors are meant to only be good for 180bhp, so it's getting a bit boarderline there.

 

There's a chip available, sonofsam is doing it at the moment, and again a DKZ cam is a good mod (I've got one, just haven't fitted it yet)

 

I've got an s16 TB if someone has a use of it.

 

Pm Sent 11.48 am 05/12/07

 

Tris

Edited December 5, 2007 by whizzer71

[colti 5]

Pm Sent 11.48 am 05/12/07

As a pug novice i presume your referring to a stock production cam fitted to the 1.9gti(engine code)DKZ?

Ta guys.

Edited December 5, 2007 by colti

[danpug 1]

Yes it from the cat equipped engine.

[Rob Turbo 3]

@whizzer71:

 

the throttle body is around 5-10mm bigger, but it also doesn't have the wedge thing on the butterfly, here's a pic I took a while ago to compare

 

 

Not a great photo I know but you get the idea, it's not a 100% straight fit, a quick guide:

 

Remove all the sensors and brackets from the s16 body and refit them the same as they are on the turbo body, I can't remember if you need to swap the sensors over or just move them around, I think you just move them around though, don't put the throttle position sensor back on though, first, remove the 2 screws holding the throttle plate in place, you will probably have to use a dremel or something to grind away the back of the screw (the bit opposite the head, it gets bent over to stop the screws being eaten by the engine due to vibration), after removing the screws, slide the throttle plate out then pull the spinde out, do the same on the turbo body. Now on the spindle out of the turbo body you need to make the slot for the throttle plate wider so that the s16 plate will fit in, I used a hacksaw and a file to do this - thread the hacksaw blade through the slot then cut down on either side of the slot, leaving a thin peice inbetween the cuts and use the file to take that bit out, once you can fit the s16 plate into the slot, put the turbo spindle into the s16 body and take note of where it catches, you will need to cut/file a couple of bits so the linkage can move freely. Once it all moves freely, slide the s16 plate back into the slot, make sure you put it in the right way, the edges are angled so that it fits right, knock the edges of the screws over with a punch or something so the screws can't come loose. You won't have a throttle stop now, it's in the wrong place on an s16 body, but that won't matter because the linkage will hold the throttle in the correct place. Now re-fit the throttle position sensor, obviously the inlet manifold will need opening up a bit now, just fit the body to the manifold, hold the throttle open and draw around the inside of the body, remove it again and you should have a mark where you need to open it up to, take your favourite hole-maker-biggerer and set about it, try to keep the alteration to the manifold smooth, clean any filings out of the manifold then refit everything, job jobbed!

 

I hope this is of some use to someone!

 

Thanks,

Rob

[whizzer71 0]

Cheers Rob !

 

[Crazy-legs! 0]

Rob do you know the O.D of the S16 body at all? I'm sorely tempted to try this on my car, but the boost pipe running from my I.C to the T.B is already very tight as im running a 4WD cozzy I.C.

 

Cheers, Marc.

[Rob Turbo 3]

The O.D. is the same as the turbo body, it's only the I.D. thats bigger

[Crazy-legs! 0]

Cheers Rob, i may have to pay a visit to my local scrappy!

Edited December 10, 2007 by Crazy-legs!

[sonofsam 5]

The O.D. is the same as the turbo body, it's only the I.D. thats bigger

 

Why not just make the I/D bigger on the turbo body? Nothing a flap wheel wont sort!