Turbo 205 GTi Lemon!
Discussion
Update time. I'm back from swaning about on super yachts.
Got back on Monday and had to rush straight from the airport to a site for work. When I finally made it home the hall looked like a sorting office. Swmbo was not impressed!
got this little puppy back. It's so cute and tiny. From all my research and chatting with the turbo guys. It's good for 270bhp. So my target 220 is well in side it's tolerance.
The rest of the stuff was just fiddley bits. You know all this things that add up. Gaskets, hose. Pipe new rad fans.
I got the turbo hung. In the week. Which was fairly simple. Although I had to cut down the studs. So now I'm getting into the rebuild. The way the turbo was set before with the intake coming up means both the intake and the pressure side want to occupy the same limited space. So whilst it's Les than ideal I've opted to send the intake Under the exhaust manifold. Gives me more room and has tha added benefit of the intake elbow not being crushed buy the servo.
As you can see it properly tight, however I think this gives me much better packaging. My only concern is heat soak.
You probably noticed the stainless hard pipes. I don't have the gas or the torch for welding Ali. I know it's heavy. But it allows me to make the pipes I need pretty cost effectively and within my skills. Maybe they will be updated later.
|https://thumbsnap.com/sbyBjp9s[/url]
Alright I'm not starting 'andy welds' Instagram just yet but its air tight.
The next issue was the the coolant return. It in the way of the new routing. So I trimmed down the seating nut. That way 50mm tall and cut and shut the pipe allowing it to miss the new intake. Don't judge my welds on this found it properly fiddly, probably not helped by being to lazy to swap out the stainless wire.
Turns out the 50mm tall nut is so you can get a spanner on it outside the turbo valley.
I managed to nip it up with some faffing.
So one of the issues I've found is the oil filler just flopping around and leaking. Also the dipstick leaking.
Further investigation I found that the oil filler pipe was split. That's a common problem so ordered a silicon replacement kit. The dipstick tube is more fun. When I removed it I found it had loom tape stopping it drop. So realised it's probably not as Peugeot intended.
Turns out I'm missing a bracket that holds both the oil filler and dipstick tube. However my dipstick tube is not the correct one .
Qué my first post on the 205 owners page. As the dipstick is available but the tube is obsolete. A fellow turbo swap owner comes to the rescue and supplys me the bracket Nd tube.
[url
|https://thumbsnap.com/jdHoSfwZ[/url]
Quick coact of black caliper paint ( had it in stock) and got them fitted.
I forgot to photo the offending bodge job I will tomorrow. I had Richard measure his dip stick to see if mine would work. Turns out mine is 100mm to long. So until he replacement arrives I won't know if its got the correct oil level or if its way out. Which is concerning.
Especially as the turbo was killed by contamination in the oil. However that has been happening for a long time some I'm hopeful that the 'rebuilt turbo' is abit of bulls
t. I have a receipt from 2017 for the rebuild. Supposedly it's not been used till this year. So either the engine is toast or its a load of codgers.
Once I have it abit further down the line. I will drop he oil and check it. If it's got glitter I will drop the pan for further investigation. However I can face that level of set back right now. I need some wins in the bag before the oils comes out
My garage looks like a bombs gone off doing my head in but I just don't have the space I need. Luckily I know where most of it is. And I have about 20 10mm's
Hopefully we're on track to get it back together. [url]
Got back on Monday and had to rush straight from the airport to a site for work. When I finally made it home the hall looked like a sorting office. Swmbo was not impressed!
got this little puppy back. It's so cute and tiny. From all my research and chatting with the turbo guys. It's good for 270bhp. So my target 220 is well in side it's tolerance. The rest of the stuff was just fiddley bits. You know all this things that add up. Gaskets, hose. Pipe new rad fans.
I got the turbo hung. In the week. Which was fairly simple. Although I had to cut down the studs. So now I'm getting into the rebuild. The way the turbo was set before with the intake coming up means both the intake and the pressure side want to occupy the same limited space. So whilst it's Les than ideal I've opted to send the intake Under the exhaust manifold. Gives me more room and has tha added benefit of the intake elbow not being crushed buy the servo.
As you can see it properly tight, however I think this gives me much better packaging. My only concern is heat soak.
You probably noticed the stainless hard pipes. I don't have the gas or the torch for welding Ali. I know it's heavy. But it allows me to make the pipes I need pretty cost effectively and within my skills. Maybe they will be updated later.
|https://thumbsnap.com/sbyBjp9s[/url]Alright I'm not starting 'andy welds' Instagram just yet but its air tight.
The next issue was the the coolant return. It in the way of the new routing. So I trimmed down the seating nut. That way 50mm tall and cut and shut the pipe allowing it to miss the new intake. Don't judge my welds on this found it properly fiddly, probably not helped by being to lazy to swap out the stainless wire.
Turns out the 50mm tall nut is so you can get a spanner on it outside the turbo valley.
I managed to nip it up with some faffing. So one of the issues I've found is the oil filler just flopping around and leaking. Also the dipstick leaking.
Further investigation I found that the oil filler pipe was split. That's a common problem so ordered a silicon replacement kit. The dipstick tube is more fun. When I removed it I found it had loom tape stopping it drop. So realised it's probably not as Peugeot intended.
Turns out I'm missing a bracket that holds both the oil filler and dipstick tube. However my dipstick tube is not the correct one .
Qué my first post on the 205 owners page. As the dipstick is available but the tube is obsolete. A fellow turbo swap owner comes to the rescue and supplys me the bracket Nd tube.
[url
|https://thumbsnap.com/jdHoSfwZ[/url]Quick coact of black caliper paint ( had it in stock) and got them fitted.
I forgot to photo the offending bodge job I will tomorrow. I had Richard measure his dip stick to see if mine would work. Turns out mine is 100mm to long. So until he replacement arrives I won't know if its got the correct oil level or if its way out. Which is concerning.
Especially as the turbo was killed by contamination in the oil. However that has been happening for a long time some I'm hopeful that the 'rebuilt turbo' is abit of bulls
t. I have a receipt from 2017 for the rebuild. Supposedly it's not been used till this year. So either the engine is toast or its a load of codgers. Once I have it abit further down the line. I will drop he oil and check it. If it's got glitter I will drop the pan for further investigation. However I can face that level of set back right now. I need some wins in the bag before the oils comes out
My garage looks like a bombs gone off doing my head in but I just don't have the space I need. Luckily I know where most of it is. And I have about 20 10mm's
Hopefully we're on track to get it back together. [url]
Edited by TheConverted on Friday 3rd September 20:41
Cheers guys,
Got a fair bit done today between the Mrs painting fences and people popping over.
I've got the turbo installed and plumbed in. Also got the intake in I might change this later on as I'm still not convinced. But it looks neat. Even had a spare heat wrap.
Still need to shorten up and route the hoses neatly. But this should get me running.
The only bodge I've done so far
Bit of good old chemical metal. For the oil feed return. There supposed to be push fit however mines looser than a prick in a tophat.
Indulged in a little mock up of the intercooler. Pressure side plumbing.
Heres the missing bracket fitted with the correct dipstick tube
As promised the getto dipstick tube
no idea why it leaked !
Also there's a special place in hell for people who cut zip ties at 45 degrees
My colleague is borrowing my chopsaw so the rest of the hard pipes will need to wait. As I have a few angles to cut.
Got a fair bit done today between the Mrs painting fences and people popping over.
I've got the turbo installed and plumbed in. Also got the intake in I might change this later on as I'm still not convinced. But it looks neat. Even had a spare heat wrap.
Still need to shorten up and route the hoses neatly. But this should get me running.
The only bodge I've done so far
Bit of good old chemical metal. For the oil feed return. There supposed to be push fit however mines looser than a prick in a tophat.
Indulged in a little mock up of the intercooler. Pressure side plumbing.
Heres the missing bracket fitted with the correct dipstick tube
As promised the getto dipstick tube
no idea why it leaked ! Also there's a special place in hell for people who cut zip ties at 45 degrees
My colleague is borrowing my chopsaw so the rest of the hard pipes will need to wait. As I have a few angles to cut.
Been super busy at work and still waiting on the loom.
Anyway got away from work at 3ish today so put a few hours in.
I've got the radiator mounted. Made up a completely new top bracket to replace the zip ties.
Quite pleased with it looks quite neat and tidy. I've also got the twin fans mounted. It only had one flapping about on the font of the rad. And I'm pretty sure it was blowing the wrong way. Peugeot intended it to have two fans and now it's got a T25 heat generator to. It's pretty close to the gearbox but I'm trying to not have to cut the bumper.
I've also got the bulk of the last hard pipe done. I need to get the intercooler mounted so I I can get the last bend done. Probably just cut a segment out as it's only going to be 15/20 degrees.
Dip stick arrived two. And it's got just enough oil to hit the bottom mark. And it was at the top mark on the bodged one.
I'm away Thursday to Sunday so hopefully next weekend I can get it finished off and running if I get the loom. Mrs might just have to accept. I'll be in the garage.
I can't really do any fab past 6 as I do actually quite like my neighbors
Anyway got away from work at 3ish today so put a few hours in.
I've got the radiator mounted. Made up a completely new top bracket to replace the zip ties.
Quite pleased with it looks quite neat and tidy. I've also got the twin fans mounted. It only had one flapping about on the font of the rad. And I'm pretty sure it was blowing the wrong way. Peugeot intended it to have two fans and now it's got a T25 heat generator to. It's pretty close to the gearbox but I'm trying to not have to cut the bumper.
I've also got the bulk of the last hard pipe done. I need to get the intercooler mounted so I I can get the last bend done. Probably just cut a segment out as it's only going to be 15/20 degrees.
Dip stick arrived two. And it's got just enough oil to hit the bottom mark. And it was at the top mark on the bodged one.
I'm away Thursday to Sunday so hopefully next weekend I can get it finished off and running if I get the loom. Mrs might just have to accept. I'll be in the garage.
I can't really do any fab past 6 as I do actually quite like my neighbors
Progress very slowly. I hate wiring so much, it's so time consuming especially when it's not something I do alot.
Got all the hard parts installed, pretty pleased with that side of things. I've got the BOV take of still to fab as I ordered the wrong size tube, and need to mount the bumper. Still waiting on some mounts for that.
I'm hoping I don't need to cut the bumper bumper until I know exactly where it sits fingers crossed.
My very getto jig for the dash to engine loom. I decided to remake it from the Haynes as the old one was so hacked up. Apart from not being able to find the plug pins anywhere it's all new. All the joints are soldered and heat shinked.
God I hate this bit. It always ends up looking abit messy. Part of me is thinking I should have ordered a self build loom for the ECU .as then the lengths would be better. I'm going to have a fair bit of excess to tidy behind the dash.
Sorry been st with the pictures again. I don't think she ever going to be a bonnet open kind of car, it's not a pretty engine anyway
Got all the hard parts installed, pretty pleased with that side of things. I've got the BOV take of still to fab as I ordered the wrong size tube, and need to mount the bumper. Still waiting on some mounts for that.
I'm hoping I don't need to cut the bumper bumper until I know exactly where it sits fingers crossed.
My very getto jig for the dash to engine loom. I decided to remake it from the Haynes as the old one was so hacked up. Apart from not being able to find the plug pins anywhere it's all new. All the joints are soldered and heat shinked.
God I hate this bit. It always ends up looking abit messy. Part of me is thinking I should have ordered a self build loom for the ECU .as then the lengths would be better. I'm going to have a fair bit of excess to tidy behind the dash.
Sorry been s
t with the pictures again. I don't think she ever going to be a bonnet open kind of car, it's not a pretty engine anyway Edited by TheConverted on Tuesday 28th September 20:11
With threads like this I often wonder whether the last owner is on PH.
Almost certainly they, or somebody that recognises the car, will be.
Probably thousands of WhatsApp groups following threads like this with the friends of previous owners poking fun following every new discovery of a bodge job.
Last owner… are you reading this?!
Great set of posts OP, that will be brilliant when done.
Almost certainly they, or somebody that recognises the car, will be.
Probably thousands of WhatsApp groups following threads like this with the friends of previous owners poking fun following every new discovery of a bodge job.
Last owner… are you reading this?!
Great set of posts OP, that will be brilliant when done.
TheConverted said:
I live just outside Southampton, and the car was in Newcastle. In some twisted turn of fate I had a Job in Newcastle last Monday. So after work I when to see the 205. It wasn't quite what i was expecting. It's quite alot rougher. There overspray that still needs cleaning up. The front bumper and lights aren't fitted right, most of the interior is loose and The exterior trim is siliconed on
However theres alot of good too I can see the potential. Comes with the original engine and gearbox, it's fitted with a xantia gearbox with a quaife LSD. The paint isn't perfect but it's really not bad I'm pretty confident I can get it spot on.
And importantly everything is there.
Back to Monday I agree to buy the car, so we load up my van with the spares. And my colleague heads back to the hotel. I followed in the 205. All seem pretty good I have a few WOT pulls and it's bloody quick. Immediate torque delivery from the turbo. Once back at the hotel, we grab a beer and set to work with the zip ties to make sure the front end stays together for the run home. (My colleague is well versed In my st choice of cars)
Couple of pictures from the guys rebuild.
Tuesday I catch up with some emails after breakfast to miss rush hour and the jump in the 205 to head home at 10ish. I start her up make a plan with my colleague about sticking together as I'm not sure I trust it. This Is when I notice it's billowing blue smoke! I switched it off and have poke round the engine and notice it has a major oil leak from the oil filler tube and water to oil cooler .
There nothing I can do in a carpark 300 miles from my tools so decided to see how far home I can get it.
Once it starts to warm up the smoke settles down and its pretty much un noticeable. The rest of the trip home is largely un eventful. There's abit of ignition break up or the ECU is cutting it on full boost when warm. (Why I'm going full boost on potentially borked turbo engine no clue )
Home safe just a load more oil to clean off the drive
Looks great !However theres alot of good too I can see the potential. Comes with the original engine and gearbox, it's fitted with a xantia gearbox with a quaife LSD. The paint isn't perfect but it's really not bad I'm pretty confident I can get it spot on.
And importantly everything is there.
Back to Monday I agree to buy the car, so we load up my van with the spares. And my colleague heads back to the hotel. I followed in the 205. All seem pretty good I have a few WOT pulls and it's bloody quick. Immediate torque delivery from the turbo. Once back at the hotel, we grab a beer and set to work with the zip ties to make sure the front end stays together for the run home. (My colleague is well versed In my s
t choice of cars) Couple of pictures from the guys rebuild.
Tuesday I catch up with some emails after breakfast to miss rush hour and the jump in the 205 to head home at 10ish. I start her up make a plan with my colleague about sticking together as I'm not sure I trust it. This Is when I notice it's billowing blue smoke! I switched it off and have poke round the engine and notice it has a major oil leak from the oil filler tube and water to oil cooler .
There nothing I can do in a carpark 300 miles from my tools so decided to see how far home I can get it.
Once it starts to warm up the smoke settles down and its pretty much un noticeable. The rest of the trip home is largely un eventful. There's abit of ignition break up or the ECU is cutting it on full boost when warm. (Why I'm going full boost on potentially borked turbo engine no clue )
Home safe just a load more oil to clean off the drive
Still kicking myself for selling my totally original non sunroof white G reg 1.9 to that pain in the a Belgian buyer back in 2011.
I need to do some work on my Clio RS182, can I ask where you got that car dolly from and is it adjustable for hight ?
Edited by neutral 3 on Friday 1st October 08:45
neutral 3 said:
TheConverted said:
I live just outside Southampton, and the car was in Newcastle. In some twisted turn of fate I had a Job in Newcastle last Monday. So after work I when to see the 205. It wasn't quite what i was expecting. It's quite alot rougher. There overspray that still needs cleaning up. The front bumper and lights aren't fitted right, most of the interior is loose and The exterior trim is siliconed on
However theres alot of good too I can see the potential. Comes with the original engine and gearbox, it's fitted with a xantia gearbox with a quaife LSD. The paint isn't perfect but it's really not bad I'm pretty confident I can get it spot on.
And importantly everything is there.
Back to Monday I agree to buy the car, so we load up my van with the spares. And my colleague heads back to the hotel. I followed in the 205. All seem pretty good I have a few WOT pulls and it's bloody quick. Immediate torque delivery from the turbo. Once back at the hotel, we grab a beer and set to work with the zip ties to make sure the front end stays together for the run home. (My colleague is well versed In my st choice of cars)
Couple of pictures from the guys rebuild.
Tuesday I catch up with some emails after breakfast to miss rush hour and the jump in the 205 to head home at 10ish. I start her up make a plan with my colleague about sticking together as I'm not sure I trust it. This Is when I notice it's billowing blue smoke! I switched it off and have poke round the engine and notice it has a major oil leak from the oil filler tube and water to oil cooler .
There nothing I can do in a carpark 300 miles from my tools so decided to see how far home I can get it.
Once it starts to warm up the smoke settles down and its pretty much un noticeable. The rest of the trip home is largely un eventful. There's abit of ignition break up or the ECU is cutting it on full boost when warm. (Why I'm going full boost on potentially borked turbo engine no clue )
Home safe just a load more oil to clean off the drive
Looks great !However theres alot of good too I can see the potential. Comes with the original engine and gearbox, it's fitted with a xantia gearbox with a quaife LSD. The paint isn't perfect but it's really not bad I'm pretty confident I can get it spot on.
And importantly everything is there.
Back to Monday I agree to buy the car, so we load up my van with the spares. And my colleague heads back to the hotel. I followed in the 205. All seem pretty good I have a few WOT pulls and it's bloody quick. Immediate torque delivery from the turbo. Once back at the hotel, we grab a beer and set to work with the zip ties to make sure the front end stays together for the run home. (My colleague is well versed In my s
t choice of cars) Couple of pictures from the guys rebuild.
Tuesday I catch up with some emails after breakfast to miss rush hour and the jump in the 205 to head home at 10ish. I start her up make a plan with my colleague about sticking together as I'm not sure I trust it. This Is when I notice it's billowing blue smoke! I switched it off and have poke round the engine and notice it has a major oil leak from the oil filler tube and water to oil cooler .
There nothing I can do in a carpark 300 miles from my tools so decided to see how far home I can get it.
Once it starts to warm up the smoke settles down and its pretty much un noticeable. The rest of the trip home is largely un eventful. There's abit of ignition break up or the ECU is cutting it on full boost when warm. (Why I'm going full boost on potentially borked turbo engine no clue )
Home safe just a load more oil to clean off the drive
Still kicking myself for selling my totally original non sunroof white G reg 1.9 to that pain in the a Belgian buyer back in 2011.
I need to do some work on my Clio RS182, can I ask where you got that car dolly from and is it adjustable for hight ?
Edited by neutral 3 on Friday 1st October 08:45
That reminds me need to work out why the sunroof isn't working
Tommie38 said:
With threads like this I often wonder whether the last owner is on PH.
Almost certainly they, or somebody that recognises the car, will be.
Probably thousands of WhatsApp groups following threads like this with the friends of previous owners poking fun following every new discovery of a bodge job.
Last owner… are you reading this?!
Great set of posts OP, that will be brilliant when done.
Did wonder if I might get some feedback back from the previous owner. To be fair I've been pretty tame on Instagram as he follows me Almost certainly they, or somebody that recognises the car, will be.
Probably thousands of WhatsApp groups following threads like this with the friends of previous owners poking fun following every new discovery of a bodge job.
Last owner… are you reading this?!
Great set of posts OP, that will be brilliant when done.
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