Here's the story of my Peugeot 205 gti 1.9 8 valve Turbo Technics turbo conversion.
I have been in awe of other peoples projects and not liked to promote my not so great abilities. The car is pretty much done now with a few things left to sort, improve and decide if i want to big power or leave it as near as authentic as I could but not sure whether to sell or let it evolve.

So, Sorry if it bores you but its been a labour of love....and has now put a huge smile on my face after using it and giving an unsuspecting db9 "a visa card priceless" moment.

After having bought her from Bath from a user on 205gtidrivers as a project with a rebuilt mi16 2.0 on carbs it became apparent all was not not good once I got it home.

picking her up "int pikey" truck



got her home fitted bonnet and washed her to see she looked grrrrrreat, engine wasnt running as wiring wasnt complete so couldnt hear it start but was told it was a rebuilt and reliable 200bhp S16 engine from another user on the 205 scene. trust oh trust.


Now over a period of 6 months after spending a considerable amount of money on her only to find the MI16 2.0 engine was scrap, within 20 mins of running it up. She ran after days of setting the timing freeing off the carbs getting the right wiring sorted and emptying the full tank of fuel as it had apparantly gone off. I ran her 200 metres at slow speed when the engine seized and we got grey emulsified oil absolutely everywhere.... (no pics as I was less than happy. It had been my intention to strip the car for parts to reclaim my loss but quickly realised when most juicy bits from it had sold that the shell and remaining running gear was just too good (despite it probably being economically sound ) to pull to bits. Roland at one point wanted the rolling shell despite actually coming near to doing a sensible deal (ie for a change not £100 for it he decided (thankfully) that he would be better off buying a complete ready to go car.


For a few months I pondered what to do truned down a few offers on what was left while I messed around iwht my 205 euro rallye and a few gti6's to get the money in to do something with the 205. I spoke with Welsh pug, Mikey S and a few others and the opinion was definitely to sell a few of the cherry bits and turn it back to standard. Now I already have a very Late Miami blue 1.9 that I nearly "gti6"ed so this really wasnt ever going to happen when just before christmas last year when I was broke and nearly penniless I had the luck (in my opinion) to come across a complete period turbo technic's engine and all ancillaries from Matty_205 after it was removed form a 205 that lost the battle with tin worm. I know he didnt want to sell but space was a problem for him and after striking a deal with him my new project money pit "part 2 the remake" commenced.


you can see how clean the shell is from this picture after the MI16 CAME OUT.



I picked the engine up in early January,2012 and collected all the bits which is accompanied with what can only be described as a thorough service history of the car that was fitted with the official peugeot "PT2" turbo kit from Turbo Technics, original invoice for complete installation and Re-engineered turbo more recently as well as a brand new Peugeot exchange engine, less than 50k ago.

The ancillaries.....

The Engine....


SOME OF THE HISTORY!!!

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306 less for first time in nearly 7 years. Lets keep it that way... please refuse any offers i make to buy your 306 ( doctors letter supplied by request)

Marmite and cheese sandwiches anyone???

Burns and Mcrae will be forever missed.
x box "yippeekayaymofo"

Due to working flat out and having a very valuable and reliable as well as competent mate as a mechanic and fellow member of the forum, Mikey S fitted the engine after much collaboration with Matt in sorting out the routing of pipe work and fitting a brand ,new oil feed pipe to the turbo as well as giving the engine and box a full service new correct plugs filters CAM BELT and fan belt water pump oils water, antifree, leads, distributor, coil battery and gearbox oil.




Sadly the turbo technics 5th injector control was not working at all with the pack not sending a signal to trigger the 5th injector set up that the 80s set up utilises for fuelling purposes. After a few weeks of contacting Turbo Technics and getting no help what so ever from them with the standard we do not support that application any longer Mike tracked down a box on the forum to Welsh pug and with Roland the "fecking big" rat passing his door to meet me for his supply of pasties and glue ( he likes to stick it up his nose allegedly) roland collected the driver ( replaced it with some slim fast ragu bollagnaise sauce mix) and delviered it to me. Luckily Ash couldnt keep his laughter in before I departed with the "tt" box in packaging and came clean and gave me the control unit and took back his Ragu sauce ( sadly)
Now the turbo technics saga didn't stop there as this unit would only fuel the 5th injector constantly what ever we did to the fuelling threshold. After bashing my head against a wall and considering heading the Tom Fenton way ( just use your DTA and be done with it which would come and haunt me 6 months later) I wanted to leave the car as period as possible due to the massive history the kit and everything about it came with. It was for this reason that I spoke to Alan jefferies http://www.enginetun...uk/about_us.htm who was good enough to put me right and repeat Mr Fentons advice and welshpugs put a mapable ecu on it and get 200+bhp without too much bother, or fit a later MF2 kit which can be used for 2d or 3d mapping map sensor pending. Now Mr jefferies knows a few things about the the original boxes and it was only his insistence that I should upgrade a little and still maintain the authenticity of the whole package I wanted.

I purchased the kit and had it delivered promptly. A month later we were no further forward other than the car would now maintain boost on the road with no problem at idle. We set up the full fuel curve carefully avoiding any chance of detonation due to under fuelling and got the car a little better but with the passenger tweeking the box on the hoof feeling very queasy we called it a day. The next morning my first stroke of luck, the car finally refused to start.

I had the car booked in for a rolling road session the following day so it was important it ran obviously. So I checked everything all leads compression test, tick, every thing as it should be, spark at leads and spark tick, fuel nope..... no fuel. pulled out the tachometric fuel relay, played around with it put it back in no difference, 3 hrs of emptying crates drawers boxes and tool boxes etc looking for one of my 15+ spares. then Mikey S came to the rescue with one " it might work it might not" and thankfully first turn of the key she burst into life, running much better than she had previously.

So I have taken her off to a friend down near Cirencester for him to rolling road it but sadly we didnt get to do this he had double booked the spot. Instead we spent a few hours getting it better set up and the difference was fantastic. She still needs to have a rolling road session to adjust the fuellng and ignition timing with the benefit of a sniffer up the ass to aid the mapping but he has finally put a big grin on my face as she makes all the right noises "alien" to me in a 205 but is really showing the signs of being a formidable clasisc street sleeper and lane cruncher.
I had a great drive through the cotswolds on the way back but know she still needs a few bits doing to make her as good as she promises to be.


and a lane to return to when she is fully on song.....

________________________________________

306 less for first time in nearly 7 years. Lets keep it that way... please refuse any offers i make to buy your 306 ( doctors letter supplied by request)

Marmite and cheese sandwiches anyone???

Burns and Mcrae will be forever missed.
x box "yippeekayaymofo"

Now after not getting the rolling road time She desperately needed and the impending doom of pugfest approaching faster than the money flying out of my wallet in 100's from demon driver buying my 306 rallye off me I had to get something done quick. I went with a mate to buy a 205 gti rear reflecctive panel and met the service manager at Roger Clark Motorsport who called me the following day to tell me he could get me into their rolling road in 6 weeks time.

So after resigning myself to not making pugfest and not being able to finish it before I tried to go off round the world I had a phone call of my mate at EJM motorsport telling me to Give Dave at MEK motorsport in Cheltenham a call as he may be able to get the car in, in time for pugfest. So 2 weeks before pugfest I dropped the car to Dave who said get it here and if I can get it in and sus out the 5th injector control unit he should be bale to get it done the week before Pugfest. So I hurried the guys up to clean my car up after it had the windscreen removed and a few blisters around the front screen aperture sorted out and the faded roof painted I was able to take it down to cheltenham but I had sold my tow vehicle the week before.

I borrowed my mates 2.1 406hdi (thanks John) and delivered it and left Dave with the keys after a brief if vague description of how the crude TT 5th injector worked. I drove home and awaited the call.....

________________________________________

306 less for first time in nearly 7 years. Lets keep it that way... please refuse any offers i make to buy your 306 ( doctors letter supplied by request)

Marmite and cheese sandwiches anyone???

Burns and Mcrae will be forever missed.
x box "yippeekayaymofo"

So the following morning the workshop was still full but it was a nice day so the business began.... time to strip out the ignition system of the old turbo technics units and standard 1.9 gear.
Out came the leads ( left ditributor in as couldnt get hold of a blanking plate ( still looking for if anyone has any suggestions) the tt ecu and injector loom and earths coil, injector rail and injectors, tps switch off the inlet manifold exhaust ( to weld in wideband Lambda and omex boss) ignition module and a few other parts. I hated doing this as it had been a right pain months before getting it all in and working and stripping it all back out was soul destroying.

heres what came out.

We then took a hole cutter and found a good place to cut the omex loom access in the bulkhead leading to another problem finding a grommet to make the whole safe and more importantly not destroy the £300 loom by chafing.

I have to say this loom felt like the best £300 I had spent that week and I spent more than a few £300 then.

________________________________________

306 less for first time in nearly 7 years. Lets keep it that way... please refuse any offers i make to buy your 306 ( doctors letter supplied by request)

Marmite and cheese sandwiches anyone???

Burns and Mcrae will be forever missed.
x box "yippeekayaymofo"

the following morning I set off to Mek Motorsport where he was mapping form scratch a caterham with a duractec on carbs. He murmurred he might be all day so I took the car of To SC auto an old rally buddy form glory days long ago, in cheltenham and proceeded to get the exhaust lambda sensor boss cut and welded on to ensure the wideband Lambda could work its magic...

stuart doing his best (on the p**s) weld.

an hour later the exhaust was refitted to the car and lambda blank fitted. The blank screwed in absolutley fine.



Next step was to get an ambient temperature sensor fitted and fit the manifold temp sensor and blank off all the pipes not needed I reloaded the car onto the trailer (12th time that week) and headed back to Mek Motorsport where the caterham was just leaving with 180brake and 170ft lb torque and a smiling pleased owner.

Dave rushed my car in tidied up the wiring to his spec and rewired the stand alone fuel pump relay to do away with the tacho that was still in the system.

We hooked her up to the rollers ratcheded her down lined the big fan up. after fitting his wideband lambda and calibrating the now update and refurbed ecu, set up the throttle pot to get linear readings as opposed to on and off readings, she was ready to be started.

She fired up first time and dave began his magic. 20 minutes went by with various short runs idle speeds and increments threw the rev range and dave shouted over to me theres still something totally wrong.

It was here that I was just going to give up. we pulled the car outside started her up and I could hear a air sucking noise and at 4 in the afternoon with 2 days to go the inlet manifold started to p**s water out. 2 of the inlet bolts were loose so I removed the complete inlet and found that the paper gasket was shot.
So with the help of adam b and a few others I located an inlet manifold gasket in gloucester collected this and a spare 1.6 inlet manifold and headed back. 9pm I had it all back together and found 2 other inlet manifold air leaks which I blanked off (job 2) needs an alloy weld in two places to complete the job and make my blanks permenant. the screw form the fuel rail that now didnt have the rail was letting air in !!!! ( what a muppet) She now started and purred from cold with absolutley no hunting or murmur. No leak form the inlet. Maybe now with 2 days to go it was going to work.

________________________________________

306 less for first time in nearly 7 years. Lets keep it that way... please refuse any offers i make to buy your 306 ( doctors letter supplied by request)

Marmite and cheese sandwiches anyone???

Burns and Mcrae will be forever missed.
x box "yippeekayaymofo"

Christ, some serious problems you've come up against! What's the latest?

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230 hp 2.1 16v XU 205 rallye on jenveys Project thread here
309 3dr K20 Type R

You sure this is a turbo technics and not an STDT?

You f**king retarded clownshoe

And for the insurance company... This vehicle is sorned and not on the road. And has been trailored to and from pugfest and not used on the road. Put that in your pipe and smoke it you scheming untrustworthy w**kers. Spend your time stopping insurance fraudsters doing cash for crash set UPS and insuring other peoples cars for nearly as much as your rip off premiums. Fir everyone elses info insurance companies are checking this forum for undeclared mods against thier databases allegedly as they can as the forum is open information. I have nothing on the road modified.

________________________________________

306 less for first time in nearly 7 years. Lets keep it that way... please refuse any offers i make to buy your 306 ( doctors letter supplied by request)

Marmite and cheese sandwiches anyone???

Burns and Mcrae will be forever missed.
x box "yippeekayaymofo"