I'm thinking of rebuilding the second 1.8 16v engine I have laying around here... (only 84k miles) Since mine (104k miles) had a shocking 14.1 mpg last tank...

So reading through several topics, and not planning to spend shitloads on it, I came to this:

xu7jp4 ported head (sandy seemed to prefer one of these to a xu10j4rs head)
gti6 exhaust manifold
gti6 inlet with 1.8 injectors
gti6 cams and pulleys
lightened crankshaft pulley and flywheel (but how much should they be lightened ideally?)

Now am I missing out anything essential?
Like do the valves&springs need to get upgraded?
Pistons & crank should be fine I guess?
Maybe I should also get the head skimmed?
And get an uprated head gasket? (or just get a new standard one...)

And also, when mapping it, how high can i put the rev-limit? 7k? It's 6250rpm now..


(yes I could drop a 6-lump in, but then I can surely forget getting through MOT here...)

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Astor 306 Francorchamps RIP
Virtual Blue 208 GTi

speaking of the clutch, keep it standard? or get an uprated Sachs clutch kit 'here'
(exedy and luk only have replacements)

Crank pulley same as the 6? (can't find much for the 1.8)

About the mpg, I may need to remark that I have 2 lambdas (both just plugged into the decat) not sure if that could be related...
Where can I find the ecu temp sender?

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Astor 306 Francorchamps RIP
Virtual Blue 208 GTi

Similar spec to the 1.8 I have in the Cab (previously jcphat's)

The 1.8 runs more power with the standard manifolds, there is no proven gain to be made from adding them, and Asim's 306 ran less than standard at an RR recently with this setup.

Also, the cams from the 6 don't benefit the 1.8 in a great way. They'd be great with a remap, but on standard they have no power (can't rely on the torque the 2.0 would have, since you're 200cc down) and the power really kicks in at 3,300rpm, it's incredibly noticeable (on a motorway in 4th, for example). The 1.8 will only rev to 6k or so, so not actually making full use of that 7,250 redline the cams are used to in a GTi6.

All in all, the 1.8 is the most reliable engine they put in a 306 (no common problems) but they suffer all manner of problems when you start playing with them.

If you're going to do it, put an XU10J4RS in. It really is an all-or-nothing thing, since you'll compromise something by adding GTi6 parts.

Edit- lightened flywheel might also cause you trouble, they can make a GTi6 stall depressing the clutch as the rotating mass is lower, so with a smaller displacement engine I could imagine the problem being exacerbated. Or I could be talking from my arse again.

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'99 1.8 XS - Sold
'00 GTi6 - Killed by armco
'01 Cabriolet 1.8 - Sold
'96 Eunos Roadster 1.8 Import

I think this graph of a gti6 head cams and manifolds, and a map to suit, disproves your theory about there being no gains from 10J4RS parts not giving gains.

its 163 bhp and 167 Nm, its over 160Nm from 3700 onwards to peak

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

Bring on the Trumpets.

hats a 100% stock bottom end, with a gti6 top end complete and a mapped ECU.

a ported xu7jp4 will give very similar if not better results from what I have heard from Sandy Brown as there's so much material to work with.

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

Bring on the Trumpets.

Mmmm, that combined with a lighter gearbox, engine and car...
Something tells me that that car may be faster than a 6 [/opens can of worms]

-somebody get me a bucket for my drool-

the remap: I've found a company that is able to do the 1.8 xsara ecu's (so same as the 306) IF it's a bosch (not the magnetti or sagem shit) and i've got both a bosch and magnetti laying around so I'll try those first..
(my second option was getting a piggyback)

the head: get a good developer or use an xsi head, got it

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Team Wheelwhore
Team Limited Edition

Astor 306 Francorchamps RIP
Virtual Blue 208 GTi

Rich_w is more or less giving away the crank pulleys now -less than O/E ones and pure engineering! My first real mod on my old car and an absolute cracker!

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I wouldn't try and lighten the original pulleys, I have seen standard ones break, you will wither need standard gti6 (or two xsi exhaust pulleys IIRC) or aftermarket alloy pulleys.

used cams in good condition will be fine

if youre going for a re-map anyway you could get PeterT to regrind the cams for more power+torque...

________________________________________

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

Bring on the Trumpets.

There may be power/torque to be had messing about with advancing the 6 cams as well. Be very careful though.

Was that dyno graph from Powerstation Mei?

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Nothing to see here

yeah now imagine that in a 309

not that I know of but it is the same format isn't it

Its Craig28 off 205gtidrivers (craig Niven) he's got OKG too (Jon M 's old Mi16 205 shell)

XU7J4RS thread linky

________________________________________

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

Bring on the Trumpets.

have a guess

________________________________________

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

Bring on the Trumpets.

plug&play if I understanded it correctly..

But the xsi head should be a better option?
(unless you get the 1.8 head ported )

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Team Wheelwhore
Team Limited Edition

Astor 306 Francorchamps RIP
Virtual Blue 208 GTi