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Author Subject: 2.1 engine build
rallyeash

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Location: Devizes

Registered: 11 Dec 2006

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Post #1
over the next couple of months i will be building a 2.1 bottom end for my 205 rallye. i already have a rebuild gti6 head with catcams and itb's to drop straight on it.
i know theres a few people intrested in the 2.1 conversion so im going to try to do a bit of a step by step guide and show all the cost of doing it.

so far ive got a bare block to build from. here is pic of it before i gave it a good clean with a wire brush and some degreaser.



looks much better after a clean, will stick up a pic tonight.
the block i managed to pick up for only

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230 hp 2.1 16v XU 205 rallye on jenveysHyper Project thread here
309 3dr K20 Type R
Posted 21st Sep 2009 at 17:06
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dannygti-6

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Location: under a car!!!

Registered: 17 Nov 2007

Posts: 517

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Post #2
will be keeping a close eye on this to see how you get on been thinking about a simialer setup for a bit

good luck!!!

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Xbox Live = Sp4n

Team one gti-6 - 2 cherry rallye's
Posted 21st Sep 2009 at 17:15
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welshpug!

Capt Pedantic

Location: Bigend, Wales.

Registered: 27 Mar 2007

Posts: 25,839

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Post #3
could use an S16 rod+oversized piston combo, as they sit 1mm below deck as standard (flat top piston)

Get the intruder and cutouts adjusted to suit the compression and clearance you need.

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need a part number? get on here - http://public.servicebox.peugeot.com

Bring on the Trumpets.

Posted 21st Sep 2009 at 17:57
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rallyeash

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Post #4
im awaiting to hear back from one company, they can supply 87mm wossner pistons and hoping they can do forged 160mm rods. then would be sorted Smile

________________________________________

230 hp 2.1 16v XU 205 rallye on jenveysHyper Project thread here
309 3dr K20 Type R
Posted 21st Sep 2009 at 18:03
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dannygti-6

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Location: under a car!!!

Registered: 17 Nov 2007

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Post #5
so your using the crnk out of a 1.9td 306 any paticular model or ar they all the same???

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Team one gti-6 - 2 cherry rallye's
Posted 21st Sep 2009 at 21:08
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rallyeash

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Location: Devizes

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Post #6
yup 1.9 td 306, citroen xantia
most xud 1.9 turbos i believe

________________________________________

230 hp 2.1 16v XU 205 rallye on jenveysHyper Project thread here
309 3dr K20 Type R
Posted 21st Sep 2009 at 22:11
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mxcrazy

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Location: hastings

Registered: 22 Jun 2009

Posts: 456

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Post #7
What about using the crank out of the 2.1 12 valve td? presumably shorter rods or pistons with a shorter pin to face height would be needed, would there be enough bore length at BDC to accomodate though?

Dont know the stroke length on it exactly but its longer again than the 1.9td, that plus the 87mm pistons?
Posted 22nd Sep 2009 at 16:40
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welshpug!

Capt Pedantic

Location: Bigend, Wales.

Registered: 27 Mar 2007

Posts: 25,839

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Post #8
that's 92mm IIRC, enough for a 2.2 or 2.3 if offset ground and big bore.

________________________________________

need a part number? get on here - http://public.servicebox.peugeot.com

Bring on the Trumpets.

Posted 22nd Sep 2009 at 16:46
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rallyeash

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Registered: 11 Dec 2006

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Post #9
i bought some red engine paint for the block and some mobil 1 motorsport 15w50 today for when shes all built up, scared of not using good oil after seeing a couple of engine on here.

sandys got me a 87mm piston and 160mm rod combo sorted out with rings and ARP bolts that will drop straight in after the blocks been machined. just need to find the cash...

also done a favour at work for a local machining company, had to get a tech drawing for a tractor crank. thought i'd drop in i need some work done and there going to sort me out Smile

will be getting on service box later as theres loads of small bits ill need from pug. luckily i have a mate there and can get a good price when he puts them on a weekly stock order Whistle

________________________________________

230 hp 2.1 16v XU 205 rallye on jenveysHyper Project thread here
309 3dr K20 Type R
Posted 22nd Sep 2009 at 18:24
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mark-house

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Location: Bury St Edmunds

Registered: 07 Apr 2009

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Post #10
How much are the pistons and rods setting you back?

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Peugeot 306 GTi 6
BMW 320 td compact M-sport
1967 Mini Cooper
1990 Jaguar XJR 4.0
Posted 22nd Sep 2009 at 23:38
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rallyeash

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Registered: 11 Dec 2006

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Post #11

________________________________________

230 hp 2.1 16v XU 205 rallye on jenveysHyper Project thread here
309 3dr K20 Type R
Posted 22nd Sep 2009 at 23:42
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mark-house

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Post #12
ooooooouch! thats a lot of notes!

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Peugeot 306 GTi 6
BMW 320 td compact M-sport
1967 Mini Cooper
1990 Jaguar XJR 4.0
Posted 23rd Sep 2009 at 00:09
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rallyeash

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Post #13
i know but you cant skimp on some items.

you can get them cheaper but the length of rod isnt correct and the pistons need machining. these ones will drop straight in.
so in the long run should be better Smile

________________________________________

230 hp 2.1 16v XU 205 rallye on jenveysHyper Project thread here
309 3dr K20 Type R
Posted 23rd Sep 2009 at 00:39
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matt h 306

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Location: Wiltshire

Registered: 22 Sep 2003

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Post #14
Are they the same rods and pistons as mine?
Posted 23rd Sep 2009 at 00:54
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rallyeash

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Post #15
im not sure mate, would believe so

________________________________________

230 hp 2.1 16v XU 205 rallye on jenveysHyper Project thread here
309 3dr K20 Type R
Posted 23rd Sep 2009 at 01:15
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rallyeash

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Post #16
picked up a complete bottom end this evening for

________________________________________

230 hp 2.1 16v XU 205 rallye on jenveysHyper Project thread here
309 3dr K20 Type R
Posted 24th Sep 2009 at 02:16
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welshpug!

Capt Pedantic

Location: Bigend, Wales.

Registered: 27 Mar 2007

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Post #17
just use the 2.0 MI16 /S16 mount, no cutting required and far lighter Smile you'll find it on a lot of 8v iron blocks too.

also, I'd recommend getting new flywheel bolts not re-using old ones, I've had some break on me, and it is advised in all the haynes manuals and by peugeot LOL

________________________________________

need a part number? get on here - http://public.servicebox.peugeot.com

Bring on the Trumpets.

Posted 24th Sep 2009 at 02:30
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rallyeash

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Location: Devizes

Registered: 11 Dec 2006

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Post #18
will do. need a few things from pug so will add to the list.

i'll see if i can pick a s16 mount would look tidier. if not a chopped 6 mount will have to do.

________________________________________

230 hp 2.1 16v XU 205 rallye on jenveysHyper Project thread here
309 3dr K20 Type R
Posted 24th Sep 2009 at 03:21
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spiky

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Location: Cardiff

Registered: 13 Oct 2006

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Post #19
cool dude Big grin

i take it you got fed up of the old setup?, shame really Sad

bigger and better, no worries with the cams again either Big grin

________________________________________

Do you need a 205 > 306 gti6 plug and go engine loom? PM ME

TORQUES for all your braided fuel line needs

MY YouTube Videos'

SUPERCHARGED 205 GTI6.... are you Fooking nuts!.... ummmm YIP Smile

268+BHP and 860kg = FUN
Posted 24th Sep 2009 at 04:06
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rallyeash

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Location: Devizes

Registered: 11 Dec 2006

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Post #20
yeah was sick of every session have to take the wheels off, get through a can of brake cleaner just to clear the oil up.

thought about just using a standard bottom end as i could have it build by the weekend but im pretty sure my cams won't clear standard pistons, so im just going to do it right and have abit more grunt tooBig grin

________________________________________

230 hp 2.1 16v XU 205 rallye on jenveysHyper Project thread here
309 3dr K20 Type R
Posted 24th Sep 2009 at 15:24
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spiky

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Location: Cardiff

Registered: 13 Oct 2006

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Post #21
yeah, must have been frustrating Sad

this is partly why i havent fitted cams Sad it's a gamble

though they are fine in my 306 gti6 Sad

________________________________________

Do you need a 205 > 306 gti6 plug and go engine loom? PM ME

TORQUES for all your braided fuel line needs

MY YouTube Videos'

SUPERCHARGED 205 GTI6.... are you Fooking nuts!.... ummmm YIP Smile

268+BHP and 860kg = FUN
Posted 24th Sep 2009 at 15:26
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t11hac

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Location: North East

Registered: 12 Dec 2008

Posts: 596

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Post #22
Just seen the tin in the photo i like it this is one of my engine with a tin LOL

t11hac has attached the following image:

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Team Black Rallye
Posted 24th Sep 2009 at 15:44
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rallyeash

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Location: Devizes

Registered: 11 Dec 2006

Posts: 4,424

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Post #23
spiky, its not the cams thats the problem. more of the mi16 bottom and gti6 head combo. just you cant get a decent breather setup sorted.

________________________________________

230 hp 2.1 16v XU 205 rallye on jenveysHyper Project thread here
309 3dr K20 Type R
Posted 24th Sep 2009 at 16:22
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spiky

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Location: Cardiff

Registered: 13 Oct 2006

Posts: 2,310

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Post #24
sorry, my reply was a bit crap.

that basically what i was saying,

and that i havent cam'd mine as the clearance issue, as i have std gti6 engine.

________________________________________

Do you need a 205 > 306 gti6 plug and go engine loom? PM ME

TORQUES for all your braided fuel line needs

MY YouTube Videos'

SUPERCHARGED 205 GTI6.... are you Fooking nuts!.... ummmm YIP Smile

268+BHP and 860kg = FUN
Posted 24th Sep 2009 at 16:23
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rallyeash

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Location: Devizes

Registered: 11 Dec 2006

Posts: 4,424

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Post #25
ahh i see, i read it wrong. yep works out alot more than

________________________________________

230 hp 2.1 16v XU 205 rallye on jenveysHyper Project thread here
309 3dr K20 Type R
Posted 24th Sep 2009 at 18:15
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