Turbo 205 GTi Lemon!
Discussion
Alright then cards on the table! I've gone and bought a right lemon. However I can see the potential, and it's going to be a fun little journey.
Here's m last build/car thread. https://www.pistonheads.com/gassing/topic.asp?h=0&...
There's only one space for one basket case at a time so the fiesta has gone.
So last Monday night I picked up this 'finished 800miles ago' 'restored and repainted' 205 1.9 GTi.
Oh I forgot to mention it's had a 406 Sri turbo engine swap as well!
Here's m last build/car thread. https://www.pistonheads.com/gassing/topic.asp?h=0&...
There's only one space for one basket case at a time so the fiesta has gone.
So last Monday night I picked up this 'finished 800miles ago' 'restored and repainted' 205 1.9 GTi.
Oh I forgot to mention it's had a 406 Sri turbo engine swap as well!
Edited by TheConverted on Sunday 15th August 22:52
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 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
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
The engine swap is loose at best. And it's running on the old 406 loom an ECU. So I immediately order an omex 600 and loom, plus all the trim clips.
Then I dig into the turbo oil feed. I've had it before when the oil feed is to big or the returns blocked. It's got an 7mm oil feed. Which is alot especially at main gallery oil pressure.
I welded up the reducer and drilled it out to 2.5mm and checked the return. There's No difference once started, so decided to pull the turbo and while I'm at it everything else that's trash. And get rid of all the original pcv system and snakes wedding of vac hoses.
Top fab on the induction pipes
Tracing back to the GTi loom and cutting out all the 406 loom.
This is where I'm upto now. Looking much tidier.
The terrifying thing is this is how many bolts were needed to get that much off it. Literally everything was zip tied in place.
Then I dig into the turbo oil feed. I've had it before when the oil feed is to big or the returns blocked. It's got an 7mm oil feed. Which is alot especially at main gallery oil pressure.
I welded up the reducer and drilled it out to 2.5mm and checked the return. There's No difference once started, so decided to pull the turbo and while I'm at it everything else that's trash. And get rid of all the original pcv system and snakes wedding of vac hoses.
Top fab on the induction pipes
Tracing back to the GTi loom and cutting out all the 406 loom.
This is where I'm upto now. Looking much tidier.
The terrifying thing is this is how many bolts were needed to get that much off it. Literally everything was zip tied in place.
Got the turbo removed, and its not good news but not the worst.
There's a good 2/3 mm of play. But I don't think it's touched the housing so fingers crossed it will rebuild. Or maybe it can be hybridised.
And turbo guys confirm a gt28 or gt25 core can go into a T25 turbo ?
Hopefully a go local to the office can help me out, with speak to him tomorrow.
So the list as it stands
Turbo rebuild
Oil feed needs revising
Coolant hoses need sorting as they are made of odds and sods.
Oil return needs revising
ECU and new engine loom.
Complete new induction hard pipes.
Oil filler repair
Oil cooler repair/replace
Service
Turbo coolant feed needs revising
New intercooler that fits
Rad fan relocation
Front bumper and lights need re alignment/ fitting
Trim re fixing with factory clips
Reverse light
Fog lights
Fit my momo (yes I kept it )
Amber indercators as I think they look much nicer.
Not bad for 6 days ownership. Fingers crossed my gut is right and I can make lemonade!
There's a good 2/3 mm of play. But I don't think it's touched the housing so fingers crossed it will rebuild. Or maybe it can be hybridised.
And turbo guys confirm a gt28 or gt25 core can go into a T25 turbo ?
Hopefully a go local to the office can help me out, with speak to him tomorrow.
So the list as it stands
Turbo rebuild
Oil feed needs revising
Coolant hoses need sorting as they are made of odds and sods.
Oil return needs revising
ECU and new engine loom.
Complete new induction hard pipes.
Oil filler repair
Oil cooler repair/replace
Service
Turbo coolant feed needs revising
New intercooler that fits
Rad fan relocation
Front bumper and lights need re alignment/ fitting
Trim re fixing with factory clips
Reverse light
Fog lights
Fit my momo (yes I kept it )
Amber indercators as I think they look much nicer.
Not bad for 6 days ownership. Fingers crossed my gut is right and I can make lemonade!
RC1807 said:
What a bummer, but, it's just as well you're as handy with he spanner so as you are.... You'll get it sorted and it'll be a hoot!
Bookmarked.
(I'd like to know more about the mk2 Escort in the garage.... Do you have a thread on that, too?)
thats one of his photos, its apparently quite nice running a pinto on twin 45s. but ill take that with a pinch of salt looking at the 205 Bookmarked.
(I'd like to know more about the mk2 Escort in the garage.... Do you have a thread on that, too?)
Thanks guys, I'm pretty motivated on this one feel like I need to dig myself out of a hole I promised the Mrs this one was done and I shouldnt need to mess with it too much. I've never see so much 
when it was puffing blue smoke and then most the front end was balanced on the garden furniture
Anyway not much progress tonight, Ive got a few part but not any major bit yet.
So set about trying to align the front end and fit the amber turn signals. Because I have no clue how its supposed to bolt up and I heavily rely on my photographic memory and the disassembly process. After a hour pissing about I relented and looked up the full bumper assembly.
I'm missing all of these bits and the metal slider bracket . Is Also missing the head light seals which might be part of why it looks so low and gappy.
Found something else fitted in a way even Colin Chapman would be impressed by. (I've decided to assume the lack of fixings is an attempt to save weight)
The fan had one zip tie at the bottom, so it was just resting on the loose Bumper
Pretty sure that's legit no more nails! Probably heavier than the clips, so that that theory out the window
the down side to no more nails, at least it's behind the body kit.
Finally some actual progress, and at least it's not a jaunty angle like the fiesta.
I also dropped the turbo off with turbo dynamics as well, should find out tomorrow what the damage is and what can be done with it.
I promised the Mrs this one was done and I shouldnt need to mess with it too much. I've never see so much when it was puffing blue smoke and then most the front end was balanced on the garden furniture Anyway not much progress tonight, Ive got a few part but not any major bit yet.
So set about trying to align the front end and fit the amber turn signals. Because I have no clue how its supposed to bolt up and I heavily rely on my photographic memory and the disassembly process. After a hour pissing about I relented and looked up the full bumper assembly.
I'm missing all of these bits and the metal slider bracket . Is Also missing the head light seals which might be part of why it looks so low and gappy.
Found something else fitted in a way even Colin Chapman would be impressed by. (I've decided to assume the lack of fixings is an attempt to save weight)
The fan had one zip tie at the bottom, so it was just resting on the loose Bumper
Pretty sure that's legit no more nails! Probably heavier than the clips, so that that theory out the window
the down side to no more nails, at least it's behind the body kit. Finally some actual progress, and at least it's not a jaunty angle like the fiesta.
I also dropped the turbo off with turbo dynamics as well, should find out tomorrow what the damage is and what can be done with it.
Edited by TheConverted on Monday 16th August 23:34
Not much progress after my initial start. Lots of bits have arrived however I need the loom to be made up, yes I'm lazy and not doing all of it myself. No doubt I'll have to do some work to it.
And I need the turbo to start on the hard pipes. Good news it it can be rebuilt and all the parts are on order to turbo dynamics.
I'm working away next week on my other job in Mallorca so not all bad
I've got all the door and rear arch trims sorted. Now which is nice
Way better than the no more nails!
The drivers side red trim was glued with epoxy as well so wasn't able to save it. Luckily I had a complete bumper trim spare so was able to make a new door one. It's not perfect but it will do for now.
Only down side is the paint was super flat and washed out. Handily I runs a vinyl wrapping company. So had just the thing in stock. My only worry is I'm going to need to do all of them now.
Also got some primer and topcoat on the damaged holes not the same colour be better than rust.
The bumper is all built up to ready to go on I just need the missing mounts.
I suspect the rear bumper has the same issue, however it looks fine so I'm not going to poke it for now
So sorry guy won't be a update till I'm back but hopefully progress will be pretty swift.
And I need the turbo to start on the hard pipes. Good news it it can be rebuilt and all the parts are on order to turbo dynamics.
I'm working away next week on my other job in Mallorca so not all bad
I've got all the door and rear arch trims sorted. Now which is nice
Way better than the no more nails!
The drivers side red trim was glued with epoxy as well so wasn't able to save it. Luckily I had a complete bumper trim spare so was able to make a new door one. It's not perfect but it will do for now.
Only down side is the paint was super flat and washed out. Handily I runs a vinyl wrapping company. So had just the thing in stock. My only worry is I'm going to need to do all of them now.
Also got some primer and topcoat on the damaged holes not the same colour be better than rust.
The bumper is all built up to ready to go on I just need the missing mounts.
I suspect the rear bumper has the same issue, however it looks fine so I'm not going to poke it for now
So sorry guy won't be a update till I'm back but hopefully progress will be pretty swift.
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 bullst. 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
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.
Bobberoo said:
With you on the wiring, and I used to install car stereos as a side line, hated pulling a headunit out of a dashboard to find a rats nest of bodged wiring!!!!
Great work with it though!!!
Oh god I've not even looked at the stereo wiring yet. Great work with it though!!!
and as it switches on and off while driving im dreading it. Slow progress. Checking and double checking my way through everything. Only got the switched live and starter wrong so far. And to be fair that's what the wiring diagram said was correct. Easy enough to switch at the plug end in the car.
The donuts came for the bumper. My lack of Peugeot knowledge caught me out, I needed some special nuts with a big flange on the back to secure the rubber.
So got my creative bodging on and made these up
I had to change the intercooler mount to fit the bumper, I only checked the intercooler space then got abit carried away with the full bar all the way across. I for got to get pictures, but it's abit neater now. Will add some later.
The bumper isn't on properly yet so no pics of it on yet.
I'm still mucking about with the wiring. I still need to fit the AFR gauge and connect that to the ECU. Tach wiring, perm and switched live for the gauge and ECU. Fan wiring, I think I'm just going to run them off the original temp switch in the rad for now. I will probably put them on a relay from the ECU eventually,to Give me more control.
I'm also trying to decide. On the boost control. I'd like to get it on a electronic switch. For the ECU to control, bit I've got a mechanical screw type one. (Not a horrendous cheapy one) and Darren from Spoox racing who's supplied the ECU, said he prefers that set up.
Be nice to have a low and high boost map though.
Just all this st to tidy up !
Although the engine is starting to look tidy.
The donuts came for the bumper. My lack of Peugeot knowledge caught me out, I needed some special nuts with a big flange on the back to secure the rubber.
So got my creative bodging on and made these up
I had to change the intercooler mount to fit the bumper, I only checked the intercooler space then got abit carried away with the full bar all the way across. I for got to get pictures, but it's abit neater now. Will add some later.
The bumper isn't on properly yet so no pics of it on yet.
I'm still mucking about with the wiring. I still need to fit the AFR gauge and connect that to the ECU. Tach wiring, perm and switched live for the gauge and ECU. Fan wiring, I think I'm just going to run them off the original temp switch in the rad for now. I will probably put them on a relay from the ECU eventually,to Give me more control.
I'm also trying to decide. On the boost control. I'd like to get it on a electronic switch. For the ECU to control, bit I've got a mechanical screw type one. (Not a horrendous cheapy one) and Darren from Spoox racing who's supplied the ECU, said he prefers that set up.
Be nice to have a low and high boost map though.
Just all this s
t to tidy up ! Although the engine is starting to look tidy.
TEKNOPUG said:
This was quite a popular conversion back in the day. You could try on 205gtidrivers.com if you get stuck (and if it gets much traffic now) but Darryl problem has most of the answers.
My Dad had a 406Sri with this engine. Was about 150bhp I think. Little low pressure turbo but was nice and smooth with minimal lag - low boost as I don't think they ran intercoolers? Go upto about 200bhp IIRC?
I had a 205 Turbo Technics at the same time. The set up was far simpler than in your car - far less hoses for a start! That had a low/high boost button and mine was running ~180bhp. They could easily run 200bhp with a proper ECU - Emerald, Megasquirt etc but you lost the old school boost characteristics. They are pretty manic on the standard 1.9 'box. I fitted a TD final drive with dragged all the gears out by 10% as I was planning to run quite a bit more power but never got round to that. Quaiffe ATB is a good upgrade to fight the torque steer.
I'm going to be running it on a Omex 600. Which more than capable off running the 4cylnder. Those early turbo technics cars were all quite basic. But they were very effective. My Dad had a 406Sri with this engine. Was about 150bhp I think. Little low pressure turbo but was nice and smooth with minimal lag - low boost as I don't think they ran intercoolers? Go upto about 200bhp IIRC?
I had a 205 Turbo Technics at the same time. The set up was far simpler than in your car - far less hoses for a start! That had a low/high boost button and mine was running ~180bhp. They could easily run 200bhp with a proper ECU - Emerald, Megasquirt etc but you lost the old school boost characteristics. They are pretty manic on the standard 1.9 'box. I fitted a TD final drive with dragged all the gears out by 10% as I was planning to run quite a bit more power but never got round to that. Quaiffe ATB is a good upgrade to fight the torque steer.
I'm aiming for 220bhp which I think will be more than enough.
She also got a citron xantia box which I believe is slightly shorter than the GTi one.
Bit of progress the bumper and grill is still only mocked up. But there light at the end of the tunnel.
Almost like it was planned. (Was definitely a fluke I forgot about the strut brace ! )
TEKNOPUG said:
I had a friend with a TT running Omex and that made ~220bhp.
TT? as in audi ? don't they make that as standard? I have it on good authority that these XU10j2te's can make a fare bit more power, however my past experience is its more trouble than its worth putting to much power through a little econo box. i want this to be fun and usable on the road and also be pretty reliable. so plan to keep the stress to a minimum. my old mk2 golf with a VR6T was an animal, but it would regularly break. nothing could cope with 400+FTLB
i'm going to run out of injectors anyway i think. probable just under 200
that's an easy fix though if i do. the T25 turbo can push tops 270 on a good day but, i think i will need a lot of supporting mods for that. Gassing Station | Readers' Cars | Top of Page | What's New | My Stuff