Peugeot 205 2.0 turbo
Discussion
Ok, well i guess it all began in April last year when i bought a 205 GTi. June of that year i swapped the orignal 1.6 8v engine for a 1.9 16v Mi16 from a 405, i wont bore u with the details of that project but the thread of which can be found here:
http://www.pistonheads.com/gassing/topic.asp?h=0&a...
All was well with that until February of this year when it decided to self destruct
So a new engine was needed. Unsure for a week or two which route to take a 2.0 8v turbo from a Xantia Activa turned up (Thanks to Mikey G) for not alot of money. That was quickly snapped up
So out with the old (well, what was left of it lol)
Not taking any chances second time around the new engine was totally stripped and rebuilt. A few pics from various stages:
Whilst the block was bare i took the chance to GUNK it and give it a lick of black engine enamel:
Back in go the pistons, rods and crankshaft:
Now the head and block are re-united it can be timed up:
It begins looks like an engine again:
Bolting the turbo back on:
With the new more torquey engine, i decided that a 1.9 gearbox would be better suited to the job, my previous gearbox would keep the engine revving too high and out of the power band. After a quick swap with a friend i had the box i wanted, just to be sure i took it to the local gearbox centre and had them strip, expect and rebuild it:
With the gearbox back and fitted to the engine , all was fitted into the car:
But it was a VERY VERY tight fit, some modifications would need to be made!!
Space between turbo and brake servo:
Space between downpipe and bulkhead:
So.... the lower engine mount was cut and welded with an increased length of 20mm. By pushing the engine forward at the bottom it tilted it downwards at the back, giving valuable millimteres of extra clearance. Combined with a brake servo from an XS i now had lots of room to play with
Whilst checking clearances the gear linkages needed to be modified to clear the turbo. The 'L' linkage that controls forward to rearward movement of the gear lever was re-drilled, cut and bent. Not only did it clear the turbo, but with my adjustable linkage rods i now had a gear selection that was tighter than a bankrupt scottishman
Even in its finished form it is very tight down the back. So with safety in mind i have heat wrapped all the fuel lines and oil/water pipes that run near the turbo and the exhaust downpipe (no pics of this):
Next up i decided to look at the airfilter and boost pipes to and from the turbo. The main boost cross over-pipe that i had sent off for powder coating returned looking better than i'd have imagined, painted an unusual silver/black speckle combo (not my idea but it does look great in the flesh), so that was fitted:
After looking at the route of the standard Xantia turbo inlet pipework it was obvious that it would foul the master cylinder and would not fit. But i wanted to try and retain the intended position of the filter, afterall its in a nice cool position as far away from the turbo as can be. So i bought some 'bling' alloy tubing and set about making up my own pipework (thankfully i have an auto bonet with the bulge, otherwise it would never have gone in):
Not too much left to do now then i had a busy few weeks ahead getting the rest of the bits ready to be fitted:
Inlet manifold totally stripped and cleaned inside & out:
Most of the wiring was installed and the ECU trial fitted (later to be bolted down on the battery tray using a custom made tray):
New alternator fitted using a custom made mount:
New, smaller fuel filter fitted into the O/S front wing:
Next up involved alot of grinding. The standard sump had extra 'wings' front and rear to bolt to the larger gearbox the Xantia had, these were not required anymore and in fact fouled against my intended radiator location. Off came the front 'wing' and a lick of paint applied:
I also fitted a new starter motor whilst it was easily accessible:
On went the inlet manifold:
Next up i needed to figure out a suitable radiator, intercooler, oil cooler combination for the front. I eventually bought a custom made alloy intercooler, an alloy radiator and fitted the Mocal oil cooler i had alrerady used on the Mi16:
Whilst welding the brackets for the intercooler i also modified the front panel slightly to clear the boost hoses and made new brackets for the radiator to drop into (The fan cowling held it in originally but i was no longer using this) and had the entire front panel rust treated and re-painted:
Brackets for intercooler:
Front panel cut and welded:
Respray:
On went the intercooler:
Next up i fitted my new 11" slimline fan, this was fitted to the rear of the radiator and would suck. Not enough room for a blow in front. Then the radiator (a new alloy item i had purchased, much lighter than a standrad rad) was fitted and plumbed in:
The fan:
With the fan shrouding no longer supporting the weight of the slam panel it proved difficult to close the bonnet as there was nothing to take the wait of the push needed to engage the latch as the panel would bend. This was sorted by fabricating 2 uprights, these go from the lower cross member to the slam panel. They also proved very usefull for securing the radiator and oil cooler:
With the radiator and intercooler in position i could finally sort my boost pipes. The idea being to keep the route as short as possible to keep lag to a minimum. I purchased some stainless steel pipe that was pre-bent, cut them and then welded them to form an S bend that would clear the top of the radiator (no oil cooler in this pic but it does fit in there, sumhow lol):
The car was almost complete now. Just a case of removing the brackets i had made for powdercoating i could fully re-assemble the rest of the car. I obviously had to modify my front bumoer to accept the intercooler without sacrficing airflow. However i didnt want to advertise the car as being a turbo, this is the best i could manage:
Well i guess thats it for now. Still a few things i need to do to get it exactly how i want it, but i'm very happy with the results
I know u'll all ask how much power it has, so...... at the moment, running standard boost i would expect about 160bhp and 180lb/ft torque (estimates) it seams to pull very well and is completely different to the Mi16, it will take some getting used to thats for sure. I hope to suprise a few unexpecting people in her
Here are a few more completed pics:
And just to confuse and suprise people
Here is a short video of the engine running and boosting, it was not at its completed stage at this point:
http://smg.photobucket.com/albums/v642/discostu_20...
I hope u enjoyed reading, all comments and suggestions welcome. I can take constructive criticism lol
I'd like to thank the following people for helping me during the conversion: a MASSIVE thankyou goes to Mikey G - for everything, couldn't have done it wihtout you!!! Tombo - for lending a hand, Matt - for the use of his welder, Kriss Aspinall - for the powder coating, Rob - for the gearbox and anyone else i'v forgotten
http://www.pistonheads.com/gassing/topic.asp?h=0&a...
All was well with that until February of this year when it decided to self destruct
So a new engine was needed. Unsure for a week or two which route to take a 2.0 8v turbo from a Xantia Activa turned up (Thanks to Mikey G) for not alot of money. That was quickly snapped up
So out with the old (well, what was left of it lol)
Not taking any chances second time around the new engine was totally stripped and rebuilt. A few pics from various stages:
Whilst the block was bare i took the chance to GUNK it and give it a lick of black engine enamel:
Back in go the pistons, rods and crankshaft:
Now the head and block are re-united it can be timed up:
It begins looks like an engine again:
Bolting the turbo back on:
With the new more torquey engine, i decided that a 1.9 gearbox would be better suited to the job, my previous gearbox would keep the engine revving too high and out of the power band. After a quick swap with a friend i had the box i wanted, just to be sure i took it to the local gearbox centre and had them strip, expect and rebuild it:
With the gearbox back and fitted to the engine , all was fitted into the car:
But it was a VERY VERY tight fit, some modifications would need to be made!!
Space between turbo and brake servo:
Space between downpipe and bulkhead:
So.... the lower engine mount was cut and welded with an increased length of 20mm. By pushing the engine forward at the bottom it tilted it downwards at the back, giving valuable millimteres of extra clearance. Combined with a brake servo from an XS i now had lots of room to play with
Whilst checking clearances the gear linkages needed to be modified to clear the turbo. The 'L' linkage that controls forward to rearward movement of the gear lever was re-drilled, cut and bent. Not only did it clear the turbo, but with my adjustable linkage rods i now had a gear selection that was tighter than a bankrupt scottishman
Even in its finished form it is very tight down the back. So with safety in mind i have heat wrapped all the fuel lines and oil/water pipes that run near the turbo and the exhaust downpipe (no pics of this):
Next up i decided to look at the airfilter and boost pipes to and from the turbo. The main boost cross over-pipe that i had sent off for powder coating returned looking better than i'd have imagined, painted an unusual silver/black speckle combo (not my idea but it does look great in the flesh), so that was fitted:
After looking at the route of the standard Xantia turbo inlet pipework it was obvious that it would foul the master cylinder and would not fit. But i wanted to try and retain the intended position of the filter, afterall its in a nice cool position as far away from the turbo as can be. So i bought some 'bling' alloy tubing and set about making up my own pipework (thankfully i have an auto bonet with the bulge, otherwise it would never have gone in):
Not too much left to do now then
i had a busy few weeks ahead getting the rest of the bits ready to be fitted:Inlet manifold totally stripped and cleaned inside & out:
Most of the wiring was installed and the ECU trial fitted (later to be bolted down on the battery tray using a custom made tray):
New alternator fitted using a custom made mount:
New, smaller fuel filter fitted into the O/S front wing:
Next up involved alot of grinding. The standard sump had extra 'wings' front and rear to bolt to the larger gearbox the Xantia had, these were not required anymore and in fact fouled against my intended radiator location. Off came the front 'wing' and a lick of paint applied:
I also fitted a new starter motor whilst it was easily accessible:
On went the inlet manifold:
Next up i needed to figure out a suitable radiator, intercooler, oil cooler combination for the front. I eventually bought a custom made alloy intercooler, an alloy radiator and fitted the Mocal oil cooler i had alrerady used on the Mi16:
Whilst welding the brackets for the intercooler i also modified the front panel slightly to clear the boost hoses and made new brackets for the radiator to drop into (The fan cowling held it in originally but i was no longer using this) and had the entire front panel rust treated and re-painted:
Brackets for intercooler:
Front panel cut and welded:
Respray:
On went the intercooler:
Next up i fitted my new 11" slimline fan, this was fitted to the rear of the radiator and would suck. Not enough room for a blow in front. Then the radiator (a new alloy item i had purchased, much lighter than a standrad rad) was fitted and plumbed in:
The fan:
With the fan shrouding no longer supporting the weight of the slam panel it proved difficult to close the bonnet as there was nothing to take the wait of the push needed to engage the latch as the panel would bend. This was sorted by fabricating 2 uprights, these go from the lower cross member to the slam panel. They also proved very usefull for securing the radiator and oil cooler:
With the radiator and intercooler in position i could finally sort my boost pipes. The idea being to keep the route as short as possible to keep lag to a minimum. I purchased some stainless steel pipe that was pre-bent, cut them and then welded them to form an S bend that would clear the top of the radiator (no oil cooler in this pic but it does fit in there, sumhow lol):
The car was almost complete now. Just a case of removing the brackets i had made for powdercoating i could fully re-assemble the rest of the car. I obviously had to modify my front bumoer to accept the intercooler without sacrficing airflow. However i didnt want to advertise the car as being a turbo, this is the best i could manage:
Well i guess thats it for now. Still a few things i need to do to get it exactly how i want it, but i'm very happy with the results
I know u'll all ask how much power it has, so...... at the moment, running standard boost i would expect about 160bhp and 180lb/ft torque (estimates) it seams to pull very well and is completely different to the Mi16, it will take some getting used to thats for sure. I hope to suprise a few unexpecting people in her
Here are a few more completed pics:
And just to confuse and suprise people
Here is a short video of the engine running and boosting, it was not at its completed stage at this point:
http://smg.photobucket.com/albums/v642/discostu_20...
I hope u enjoyed reading, all comments and suggestions welcome. I can take constructive criticism lol
I'd like to thank the following people for helping me during the conversion: a MASSIVE thankyou goes to Mikey G - for everything, couldn't have done it wihtout you!!! Tombo - for lending a hand, Matt - for the use of his welder, Kriss Aspinall - for the powder coating, Rob - for the gearbox and anyone else i'v forgotten
Edited by DiscoStu on Monday 4th June 23:20
WOW!!!
I remember reading the original post up to the point where teh Mi16 gave up the ghost and you were looking into a Xantia turbo engine............REALLY glad you went through with it!
The automotive world is a better place for people such as yourself taking gambles and working through problems that would ordinarily put other people off doing such a brilliant conversion!!!
Awesome
I remember reading the original post up to the point where teh Mi16 gave up the ghost and you were looking into a Xantia turbo engine............REALLY glad you went through with it!
The automotive world is a better place for people such as yourself taking gambles and working through problems that would ordinarily put other people off doing such a brilliant conversion!!!
Awesome
_dobbo_ said:
Actually quick question - in this picture:
I can see you've relocated the plate to the front valance to open up airflow to the intercooler - on my GTI the vent in the front valance is blocked up with plastic - was yours like this or was it always open?
both my 205s had a plastic panel behind the lower aperture - it's held on with split washersI can see you've relocated the plate to the front valance to open up airflow to the intercooler - on my GTI the vent in the front valance is blocked up with plastic - was yours like this or was it always open?
pacey205 said:
There should be plastic blocking off that lower grill as standard. It is only removed in countries where the temperature is higher. As said its just held on with split washers so you can pull it off no worries. I have removed it on mine.
It's coming off on mine this weekend, with summer almost here my running temp on the motorway is a little bit higher than I'd like._dobbo_ said:
pacey205 said:
There should be plastic blocking off that lower grill as standard. It is only removed in countries where the temperature is higher. As said its just held on with split washers so you can pull it off no worries. I have removed it on mine.
It's coming off on mine this weekend, with summer almost here my running temp on the motorway is a little bit higher than I'd like.looking good.
paulrhodes said:
That looks fantastique! If I was going to get another 205 (would be my forth), I'd be offering you as much cash as I could beg, borrow and/or steal.
Congrats fella. Great job
my last one is being taken away today to the big scrap yard in the sky Congrats fella. Great job
on the hunt for my 3rd - addictive aren't they
sleep envy said:
paulrhodes said:
That looks fantastique! If I was going to get another 205 (would be my forth), I'd be offering you as much cash as I could beg, borrow and/or steal.
Congrats fella. Great job
my last one is being taken away today to the big scrap yard in the sky Congrats fella. Great job
on the hunt for my 3rd - addictive aren't they
There's definitely something addictive about that slightly psychotic handling that keeps you going back.. it's the automotive equivalent of crystal meth.
Gassing Station | Readers' Cars | Top of Page | What's New | My Stuff