Hi! I'm new (but most people call me Martin)

I have a 306 XSi 2.0 16V Phase 3 here and basically the engine died

So, got a hold of a phase 1 GTI-6! which was rusted to hell.

We've put the GTI-6 engine in coupled to the XSi 5 speed box into the XSi with the XSi original loom and injectors.

Everything was going fine until it came to fitting the inlet manifold.

Physically it fits, we changed the map sensor (since phase 1 and 3 connectors are different)

naturally we assumed all would be well.

When we started the engine it was as if there is a vacuum leak.

It hunts between 800rpm and 4000!

So, are the other sensors between phase 1 and 3 internally different? (not including the map as we fitted the XSi map sensor to the GTI6 inlet manifold as it was a direct fit)

currently we've got it idling at 1000rpm with the ICV blocked off. there is no EML on either.

The car drives well like this, no noticeable loss in power


this is turning into a lot of work for not such a great gain!

I'd appreciate any halp


edit: I've just been looking at the gallery and I remembered something!

Does the vacuum pump have to be connected to the inlet manifold? and does it T off with the brake servo? I don't remember what the GTi-6 bay looked like when the engine was removed - because I didn't remove the engine.

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genuine nob

wouldn't have even tried using anything xsi related on the 6 engine, surely it'd have been easier to swap the whole lot over even the box

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306 rallye reproduction decals (full sets/individual decals) | 306 b-pillar textured vinyl weatherstrips
306 slam panel esso stickers | 306 yellow / orange / pension fund red side door badges
gti6 inlet manifold badges | 306 rear boot badges (p2/p3)
winner of Extraction of toys from prams with outstanding vigour award 2009 [source: gti6 owners club]

It needs 6 management to go run it, you need to install the ECU and loom from the donor car or else this project is never going to run right.

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"Supercharged - 454.1bhp/317.5lb/ft"
Peugeot 306 GTi-6
2000 (X), Moonstone

It was running just fine with the XSi inlet on it though and with the XSi management.

Wasn't running lean either! (which I was not expecting)

Just had the problem since fitting the GTI-6 inlet only.

I don't want you to tell me what should have been done - because I know what should have been done, Ideally I would have swapped the looms. I'm not new to engine conversions - well I am on a 306 :p

Shell is too good to scrap and it's all declared.

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genuine nob

yup, the GTI6 loom is damaged because it was cut when the engine was removed!

I could fix it but I'd need new wire and patience - I lack both

I just figured that since the XSi is a 2.0 16V, the GTI-6 engine would at least run on XSi management. (a little bit like running a TU5JP4 engine on a J4 loom in a 106!) so we decided to leave the XSi loom in rather than source a GTI-6 one. sounds silly I know, but as I said already it did run fine with the XSi inlet on it.

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genuine nob

I did wonder that.

The reason I'm asking is because someone was arguing (I love a good argument me) with me that the sensors were the same and I said they were different across the phases probably, because I was a bit unsure myself having never worked on a petrol 306 before.

I think the ICV is the problem since, as you say, the wiring is different. it's stuck open allowing it to rev really high?

Just gonna shove the XSi inlet back on :p

I appreciate the help!

No doubt I will be back! I'll let you know how I get on with it. Probably won't be today as it's not at my house, and the 106 doesn't like the snow so I can't get to it.

I'm only comfortable with the old DTurbo's

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genuine nob

I've put a 1998 Gti6 engine into an XSi shell, i used the same loom and ECU that came with the engine and gained no problems. I'd definitely change the loom over and then you will solve the issue.

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Richies Project Rallye

Electrical work carried out in Portsmouth

- Top Tip!!!

Its easy to change the loom mate, it sounds daunting but trust me theres not a great deal to it, you have fitted an engine which is harder than the loom, you will find it much easyer to do the loom and ecu.
And seen as you have allready fitted the gti6 engine, for the little tiny bit of extra work you may aswell have it running like it should and get the gains.

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andrew315rawson@live.co.uk
Moonstone phase 7 gti6
My Project thread: http://www.306gti6.com/forum/showthread.php?id=119992&page=1

Guys, it runs now!!!!!

I freed the multimeter from the tool bag.

GTI-6 ICV was buggered, jammed open.
GTI-6 MAP sensor has higher resistance - so it was running really rich.

All the other sensors are the same as the XSi ones

Simply fitted the XSi ICV into the GTI-6 inlet housing.
butchered (electrically perfect ) the XSi MAP sensor.

The car now seems to run correctly, only a proper drive will tell. There's no inlet popping on full throttle/load so if it's lean it's not by much. and there's no flames so it's not rich.

I'll get the AFR checked, if it's very wrong then GTI-6 loom time

I know it seems like I'm not taking your advice, but wiring on cars in general is doing my nut in at the moment :p

I do see that the loom is very simply to swap though!

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genuine nob

I'm not really worried about the rev limit for now. More concerned for the fuelling.

As for the timing, it's not knocking, so for now it's "safe"

What is the rev limit for the XSi 2.0 16v?

I know the GTI6 is about 7250 ish.

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genuine nob

Compression ratio on an XSi lump is 10.4:1, whereas the 6 lump is 10.8:1. As Welshpug says the whole setup will not be correct, doing what you've done is fine but it is not correct the engine will suffer for it in the long term.
You could change the loom and ECU over in 30 minutes and it would be running perfectly.

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"Supercharged - 454.1bhp/317.5lb/ft"
Peugeot 306 GTi-6
2000 (X), Moonstone

Yes you'll need the ECU unlocked, only so it doesn't lock up straight away with the immobiliser plugged in. (Unplug the immobiliser before you start it, you might need that re-coded?) Maybe some of the more experienced members can help with this.
I can't answer the loom question, my engine and loom was a 98 going into a 98 Xsi, i'd suggest getting a phase 2 loom maybe?

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Richies Project Rallye

Electrical work carried out in Portsmouth

- Top Tip!!!

Yes, on the Phase 1 if you disconnect the keypad when the immobiliser is unlocked it will stay unlocked.

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"Supercharged - 454.1bhp/317.5lb/ft"
Peugeot 306 GTi-6
2000 (X), Moonstone