[engine_work] 309 Gti6 Conversion

[felix2566 2]

Hi all. A little introduction, have been a member of this site for a few years and love it. Is by far the best site for car related information!

 

I have been working on my 309 for about 6 months now getting it ready to put a GTi6 engine in. I thought it was about time that I shared my project with every one else on here.

 

This is my baby that I am working on!

Edited December 17, 2007 by felix2566

[felix2566 2]

The 8 valver came out and I got on with cleaning up the engine bay. Looked like over the years the engine had been doing its own form of rust prevention!

 

De-rusted and primed all the affected areas ready to be painted.

Sofar I have fitted new driveshafts, wishbones, droplinks, full set of Baker bushes, braided brake lines and 406 master cylinder.

[Stu 18]

Excellent project mate, i think ill do a 309 next..

 

By the way, if your going over to 6 power, then do you fancy selling me your carbs?

[felix2566 2]

Because the car was previously running on carbs I have now fitted an in-tank fuel pump and will soon be fitting new fuel hoses, (when they arrive!)

 

Work has been also done to the new engine, new clutch kit, cambelt and manual tensioner, and reconditioned BE3 gearbox. Also because I do not have PS I have fitted all the alternator bracketry and engine mount to allow this.

 

When I got the car it had already been stripped out and had a roll cage fitted etc. I didnt like the way the seats were mounted to the floor. Four pieces of angle ally bolted through the floor and then to the seats, wasnt very stable! I am half way through making some new ones which will be much better.

 

I have been slowly collecting lots of parts for this engine mainly through people from this forum, I would like to say thank you very much for the parts and the info that I have been able to get by going through loads of posts! Not that I mind reading all the stuff that is on here, thats what lunchbreaks are for?!

Edited December 17, 2007 by felix2566

[felix2566 2]

Sorry Stu, have sold them a while back!

 

One thing that I have been thinking but have not seen mentioned is, the fork that holds the lower engine mount is mounted with a rubber bush, do people uprate these? Mine is easy to move around by hand, I was thinking if all the othe rmounts have been uprated, shouldnt this be changed too?

Edited December 17, 2007 by felix2566

[Alastairh 47]

Looking good.

 

Them wheels quite suite the car aswell.

 

That new wishbone. Can i suggest you measure it/compare it the original 309 item to check you have the right part from your suppliers. From my experience which has been passed on by others that that new wishbone with the ribbs looks like a 205 item, where as the 309 one doesn't if you look back at the pic.

 

Al

[Anthony 1,003]

That new wishbone. Can i suggest you measure it/compare it the original 309 item to check you have the right part from your suppliers. From my experience which has been passed on by others that that new wishbone with the ribbs looks like a 205 item, where as the 309 one doesn't if you look back at the pic.

Looks like it's adjustable in length anyway as the balljoint part appears to be threaded.

[Alastairh 47]

Looks like it's adjustable in length anyway as the balljoint part appears to be threaded.

 

Now that is a good point!

 

Jeez Ant, how close do you sit to your screen?

[d-9 0]

Nice project mate, love the ole PTS kit. You ever park up behind cafe rene? Sure Ive seen this car around somewhere.

[BERTMAN 40 1 Cars]

nice project, your 309 looks ace!

[Emmy Seize 8]

Now that is a good point!

 

Jeez Ant, how close do you sit to your screen?

 

Probably one of the benefits of being short-sighted (I also noticed the adjustability straight away)

[SamGTi 0]

Sorry Stu, have sold them a while back!

 

One thing that I have been thinking but have not seen mentioned is, the fork that holds the lower engine mount is mounted with a rubber bush, do people uprate these? Mine is easy to move around by hand, I was thinking if all the othe rmounts have been uprated, shouldnt this be changed too?

 

At the beginnig of this thread you mentioned you have a full set of Baker mounts - did this not include the lower engine mount? (mine did!)

[kate205gti 4]

ooh nice project bring it to llandow

[jackherer 543]

At the beginnig of this thread you mentioned you have a full set of Baker mounts - did this not include the lower engine mount? (mine did!)

 

He means the one at the base of the fork, where it bolts to the subframe. They are available from Peugeot apparently, although I've never changed one and my engines dont move at all on group n mounts.

[mos 1]

He means the one at the base of the fork, where it bolts to the subframe. They are available from Peugeot apparently, although I've never changed one and my engines dont move at all on group n mounts.

 

they are about £8 from peugeot if memory serves

[SamGTi 0]

He means the one at the base of the fork, where it bolts to the subframe. They are available from Peugeot apparently, although I've never changed one and my engines dont move at all on group n mounts.

 

You really do learn something new every day

[felix2566 2]

Thanks for all the comments people!

 

You are right the wish bones are adjustable at the hub end, and solid bushes at the subframe end.

I was talking about the bush on the fork, will have to see if I can get another one from Pug, mine seems really wobbly!

 

D-9, yes I have been parked around by Rene, one of the better pubs in Gloucester. The car came with a PTS back bumper and side skirts but the front was original GTi. Just by chance I found some on ebay front and back, wone it for 99p, looked at the guys history, he had paid £50 one month earlier! I am not really into body kits at all, but since it is original Pug stuff and it suits the car I am happy to have it on my car!

 

Kate, I deffinately intend to take it to plenty of track days when its done, just a case of getting it done!

[felix2566 2]

Sam, I got the bush from Pug, was £6 something! Is quite a bit stiffer than the old original, looked like it came from the factory with it!

 

Last night I had a trial fit of the engine and a look at what I still have to do to get it running, and after having read all that is on here about this conversion I had some questions......

 

1. I am changing from a BE1 box to BE3, I seem to remember reading somewhere that there is a difference in cables and pedels, is this correct?

 

2. I am getting a dual outout speedo drive for the ecu and dash, will I still be able to use the standard 309 cable?

 

3. The big one, cam cover to MC clearence! There are some different ways of getting round this.

1) Lower the engine mount, space the GB mount and extend the lower mount. But, wont this mean that the lower mount will be contantly be pressed down because the engine has been lowered? Is this OK?

2) could I not space out the bottom of the whole MC and SC out where it is connected to the bulk head, and then grind a bit off the bottom of the MC?

 

4. I know that there are issues with exhaust manifold to bulk head contact, is that one of the reasons for extending the lower engine mount? If one does extend the lower mount, how much?

 

Sorry for all the questions, but I have been reading so much on here, I just wanted to clarify some things before going ahead?

 

Cheers!

Edited January 11, 2008 by felix2566

[felix2566 2]

Oh, another thing, my battery is in front of the passenger seat, where can I get those thick cables from, to go from battery to engine?

[d-9 0]

No ideas on the other questions, but when ur going from a be1 box to a be3 box, u need to swap either the clutch release arm in the box or the clutch pedal and cable, Id go with the cable/pedal as its easier the be3 clutch action is much nicer. Think Ive got a spare be3 pedal and cable in the shed if u want them.

[felix2566 2]

d-9, if you have a spare pedal and cable that would be great! Drop me a PM and I could come and collect it for some beer tokens

[felix2566 2]

Even though I was at Autosport I managed to make some good progress on the car. The engine is in...... well almost. The Gbox mount is attached. But the other two will need work to get them to fit. I will have to grind a bit off the cam cover to make space for the master cylinder. The lower mount will have to be extended too. I havent found a measurement yet on here as to how much people have extended it, so will probably see what looks good.

 

The reason why it is so low down in one of the pictures is because it is not suspended by the mount, there are a load of blocks on the floor holding it up!

Edited January 14, 2008 by felix2566

[felix2566 2]

Did a trial fit of the front slam panel to see what space there was going to be, I know that 205's always have problems fitting it all in. It looks like there will be plenty of room to have the radiaor in the correct position and still have easy acess to the oil filter.

 

When I fitted the new cambelt etc, I also put a one piece cam pulley on to replace the two part rubber bushed Pug one. When I started the cambelt chabge the cam pullies would line up with their timing holes but the crank timing hole was out of alignment by about 5-10 degs. I assume that it has slipped a bit. Once I put the new pulley on the timing was all perfect, all the pins line up!

[Edp 67 3 Cars]

Nice thread and interesting to see how it all fits together as this is what i will be doing rather soon. Keep up the good work fella.

[Banjo 1]

Hey dude lookin good! You'll have to take me for a spin when its all done, and i'll take you out in my Golf

Ben