205 Gti Turbo Conversion

[ronnie_gti 0]

whats part are needed to fit a 406 2L turbo lump into a 205 gti?

 

i have the hard part of the wiring loom just need to know what else i need etc.

 

i also have a 1.9 gearbox.

 

anything else needed?

 

cheers for any help

[Hilgie 16 2 Cars]

Do a search please and remove the pic from your sig. Thank you.

[ronnie_gti 0]

can i use a standard gti flywheel and clutch or is it better to hav the mi16 clutch and flywheel?

 

and which car do i get the enginemount from to fit? is it he pug 306 xsi the 306 or something else? and what the difference betwen the one you get of the citroen engine?

 

and any recommendations on intercoolers for this?

 

chers

[Hilgie 16 2 Cars]

standard GTi flywheel allows only 200mm clutch wich is far too small...Mi16 is a better option. If you have a 406 lump then the upper part of a 306 XSi or S16 is the one to have (2.0-8V or 2.0-16V). If you have an XM lump then the upper part of a 1.9 Mi16 is to be used.

 

Intercooler from a BMW 325TDS or Sierra Cossie 2WD will do fine.

[sonofsam 5]

whats part are needed to fit a 406 2L turbo lump into a 205 gti?

 

i have the hard part of the wiring loom just need to know what else i need etc.

 

i also have a 1.9 gearbox.

 

anything else needed?

 

cheers for any help

 

Gearbox Vehicle speed sensor. (VSS)

unlocked ECU.

modification to water pipe's.

^ ^ to gear rod(s)

8v crank pulley/lower engine mount, extended lower mount fork by 15mm

custom/modded exhaust/downpipe.

new fuel lines to route out of the turbo's way.

longer throttle cable (not essentail , but alot neater)

Air filter/Boost pipes/intercooler - http://www.student.kun.nl/p.oonincx/Intercooler.html

[ronnie_gti 0]

what needs to be done to te Gearbox Vehicle speed sensor. (VSS)? any way to overcome this?

 

any clue on where bouts to reloate the fuel lines to?

 

what sort of moddifications need to be done to the water hoses?

 

and what throttle cable would you recommend?

 

be that took some time to do ur's? i like that. hopefully mine will turn out like it.

[sonofsam 5]

what needs to be done to te Gearbox Vehicle speed sensor. (VSS)? any way to overcome this?

 

any clue on where bouts to reloate the fuel lines to?

 

what sort of moddifications need to be done to the water hoses?

 

and what throttle cable would you recommend?

 

be that took some time to do ur's? i like that. hopefully mine will turn out like it.

 

 

You need to fit a VSS on the gearbox instead of the 205 plastic speedo drive, it looks like a regular speedo drive, but has a 3 pin plug connection, this allows use of the 205 speedo cable and a plug connection for the turbo loom/ECU (£70 from pug or there abouts or you may get lucky down the breakers!) Nope no way to overcome this im afraid, if you dont fit one you will have very bad MPG by all accounts!

 

Rubber fuel lines just need extending from the metal pipe's on the bulkhead upto the fuel rail on the manifold, it's mainly the return line

that is best to route around the wing and down to the metal bulkhead pipe.

 

Water hoses will need a few Tee junctions for everything to function correctly, mainly if you are using the heat exchanger? plus the

turbo water feed needs an expansion outlet ( plans are on the search for this)

 

Throttle cable is a universal 405 item from ECP or the like, can be cut to any size needed.

 

..Thanks, yes I took my time to get it so I was happy with everything, she has been faultless so far

[ronnie_gti 0]

what does the VSS come off? i aint lcky so i better buy one from pug, anyone no the part number for the part?

 

i get ya with the fue lines.

 

plans? what search? where?

 

i get ya bout the throttle able, mite b a good idea if i add thatto my shopping list. only a few more bits needed, the harder bits to get hold of and the more expensive bits.

 

cheers for ur help by the way its much appreicated. (sorry for spelling)

[sonofsam 5]

The search function on this site is at the top of the page on the right, next to the help button.

use it and type in 'Turbo' for starters and it should bring up loads of topics for you to browse through.

If you put in 'search under username' - sonofsam, you should find the water hose plumbing topic I put up a while back.

 

Part no,. for the VSS came up quite recently in another topic I think, may have a look later for yuo, unless

you find it first on the search!

 

Yeah their are a good few 'bits' to source for this conversion, that's what takes some of the time and effort looking and off course money!

[ronnie_gti 0]

is ur first digram rite then? as there are quite a few.

 

does the oil cooler co as standard on the 406 turbo engine as i pick my engine up 2morz. ust a little help note to meself.

 

ok cheers fella, i had a look but all i found out is that they are from a 306 gti6.

 

well atleast i got a few of them. still loads more to do

[sonofsam 5]

The first diag. is not mine, but that of Alex_G,s , it is right yes, however I think I ended up doing mine a little

different although the principles are the same. really should update that thread with how I did mine!

But if you follow Alex's you wont go far wrong.

 

VSS were on some Citroens also, maybe AX or even Pug deisel too.

 

Oil cooler is more of an oil 'warmer' known as a heat exchanger, it will in effect heat your oil quicker using the coolant supply

as to get the oil upto running temp. quicker, yep there are as standard.

[colti 5]

what does the VSS come off? i aint lcky so i better buy one from pug, anyone no the part number for the part?

 

i get ya with the fue lines.

 

plans? what search? where?

 

i get ya bout the throttle able, mite b a good idea if i add thatto my shopping list. only a few more bits needed, the harder bits to get hold of and the more expensive bits.

 

cheers for ur help by the way its much appreicated. (sorry for spelling)

Not long bought a 205 with an RGY XM motor in it.The VSS isnt wired in.Did a diagnostic on the ECU and there were no fault codes for an open circuit VSS stored,so i guess it wasnt missing it.

Amitedly there's no lambda sensor connected either(Again no fault code)but as far as i know the speed sensor only allows the ECU to hold the idle valve open slightly when the cars rolling thus preventing a stall when u come to rest.

Am stripping the motor out to do the conversion properly btw.

[sonofsam 5]

Ronnie, you will also need a lambda sensor boss welded into your downpipe exhaust for fitment of a lambda sensor.

Demon tweeks sell the bosses or you can use an appropriate sized nut.

[M@tt 77]

ronnie look here for VSS sensors if you need one

http://forum.205gtidrivers.com/index.php?s...c=83599&hl=

 

also frindly bit of advice pal before mods let you know, txt speak isn't allowed on the forum, smacks of chav which i'm sure you're not, so full plain english please my good man

Edited December 8, 2007 by M@tt

[ronnie_gti 0]

right a little update.

 

i now have the engine in my hands with only 70k on the clock, the loom to go with it and a 1.9 gearbox to.

 

all i have to get done is he ecu unlocked and buy me a mi16 flywheel, an intercooler and a clutch.

 

for the clutch i was thinking of getting an AP racing clutch, unless anyone has any ides they coud throw at me?

 

there was a mi16 ally flywheel on ebay but not now. would this do?

 

and maybe a 205 xs brake master thingy (sory can't hink at what its called atm) to help with space around the turbo?

 

i want to do this properly first time.

 

cheers for everyones help.

[bales 1]

I use a mi16 clutch and a standard flywheel and it is fine, with the VSS sensor I have run mine both with and without it connected and it has made no difference to performance or mpg or boost control.

 

The master cylinder is fine aslong as you extend the lower engine mount to tilt the engine.

[ronnie_gti 0]

i undestand you there fella. are the gti6 and mi16 the same flywheel? if i bought an gti6 flywheel what clutch would i need to use as there are 2 for the mi1? does this matter?

 

cheers

[craig f90 0]

I get confused with this BUT i know for certain one clutch is push type and the other is pull type. i would find out if an mi16 clutch will fit your flywheel. Or you will have to modify/change the fork and clutch lever. Something that will for certain add more cost/stress and time to your conversion. Do a search fella, Ive read that much info on here through using it, ive learned so much. If i was really stuck i asked questions then.

Edit:

search for: 2.0 turbo project 2007 questions. Most of the answers are on that post.

Edited December 9, 2007 by craig f90

[ronnie_gti 0]

had a little look on there, i have read/understand most of it. just need to find out about the fywheel and clutch sarga now. then i can get this thing rolling into action

[Crazy-legs! 0]

Hiya Ronnie, I used a GTI6 flywheel for my conversion, which was the same as an MI16. I think an S16 flywheel is also the same. As far as clutch's go, i think i used a 1.9 MI one. Its just a standard LUK item and i havnt had any grief whatsoever. (And thats running 186BHP, and 220lbft at the fly!)

 

Hope this helps, Marc.

[danpug 1]

Whats the spec of yours crazy-legs?

[Discostu 6]

I'v used an mi16 flywheel that i'v had re-surfaced and balanced with a (Valeo) mi16 clutch. No probs so far with 242lb/ft @ fly

 

Also using an XS brake servo to give a bit of extra room, no effect to the breaking system, just a stiffer pedal

[Crazy-legs! 0]

Whats the spec of yours crazy-legs?

 

0.8 bar (12PSI) of boost, full scorpion exhaust with modified down-pipe, 4WD Cozzy FMIC, moddified breather system and a home-made induction kit using a ram-air filter.

 

Thats about it! I havnt really done that much to it.

[danpug 1]

Nice power!

[Crazy-legs! 0]

Cheers Dan!