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Author Subject: GTI6 manifold on 1.8 ph3
jcphat

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Post #1
Iam trying to improve the performance of my cab and have in mind a manifold and throttle body. I already have a reflex back box. I figured there may be some wisdom here. Any advice on consequential mods and set up?
Thanks

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Posted 11th Mar 2008 at 03:10
stan_306gti6 Forum Admin

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Post #2
The inlet and exhaust manifold will benefit your engine a lot, the exhaust manifold is a direct swap, whereas the inlet manifold may require you to lengthen some of the sensor wiring possibly...Unsure

Should see a healthy gain anyways. Yes

Stan.

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Posted 11th Mar 2008 at 05:03
keith

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Post #3
as stan says you should get quite a decent gain from it, considered fitting the exhaust manifold and cams ? also worth doing. not very expensive either!
Posted 12th Mar 2008 at 02:52
jcphat

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Post #4
Looking for exhaust and inlet(on e-bay) and have a gasflowed throttle body already purchased. What would I pay for cams-fitted?

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Posted 12th Mar 2008 at 03:40
24seven

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Post #5
the exhaust will also require a gti-6 downpipe/cat as well. the inlet should be a straight swap, as with the cams (though the timing may need perfecting, something I don't know about... yet). both the inlet and exhaust manifolds will see a decent gain, as these are VERY restrictive on the 1.8.

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Posted 12th Mar 2008 at 05:41
birk

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Post #6
i have an exhaust manifold for sale £65 deliverd

Dan

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Dan
Posted 12th Mar 2008 at 18:27
stan_306gti6 Forum Admin

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Post #7
Roll eyes

Always the salesman Birk....LOL

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Posted 12th Mar 2008 at 21:19
birk

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Post #8
stan_306gti6 wrote:
Roll eyes

Always the salesman Birk....LOL


LOL it is my job, money must be earnt

I'd recomend to get it done aswell, a few ponies can be had from these engines.

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Posted 12th Mar 2008 at 23:52
keith

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Post #9
will be interesting to see the results if someone does do this, as these engines are common as muck, can be picked up for a few notes.
Posted 13th Mar 2008 at 01:37
keith

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Post #10
jcphat wrote:
Looking for exhaust and inlet(on e-bay) and have a gasflowed throttle body already purchased. What would I pay for cams-fitted?


speak to petert, he does good regrinds.

best and cheapest option. imo.
Posted 13th Mar 2008 at 01:38
24seven

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Post #11
quick update, just done this swap on mine. The XS stepper motor doesn't fit without a fair bit of grinding/drilling/filing to make the bolt holes line up and fit. Also some of the A/C pipes coming out of the pump may get in the way (my a/c is shafted anyways so I just 'encouraged' the pipes to sit a more convenient location). And yes, some of the sensor wires will need lengthening.

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Posted 21st Mar 2008 at 01:18
stan_306gti6 Forum Admin

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Post #12
Difference to performance is?? Unsure

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Posted 21st Mar 2008 at 03:30
24seven

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Post #13
for me at the moment it's not running right, so I can't say.

To add to my previous post, you'll also need GTi-6 fuel rail and stepper motor housing (on the xs the stepper mounts directly to the TB, but on the 6 it has a seperate housing and air feed). also you need to swap the sensor from underneath the xs manifold (inlet pressure sensor?) for the similar one on top of the GTi manifold, as the connections are different (it's only 1 bolt to swap, both are3 pin but the xs one is smaller), the injector loom and some of the sensor loom around the TB neds to be free'd up from the rest of the loom otherwise it won't reach (yellow 2pin tps plug and white 3pin something plug), and the manifold fouls the radiator top hose without some persuasion (I removed the forward of the 2 clamps holding the arm on, but make sure to put the bolt back afterwards, as it also holds the gearbox on). Finally, some of the breather system hoses need modifying as well, so having a set of GTi hoses would be handy (particularly the ones from the rocker cover to the tb/inlet).

the xs fuel rail can be made to fit, but it requires the mounts shortening and some L shaped brackets carefully fabricating to clamp the rail down, though it'd be a lot easier to swap for a 6 rail instead if you have one.

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Posted 21st Mar 2008 at 21:40
marc l

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Post #14
Did the gti6 exhaust manifold go on nicely and did you use the xs cat?

cheers

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1999 WHITE Phase 3 GTi6 Big grin
1991 Peugeot 205 1.6 GTi - Track Car


Posted 21st Mar 2008 at 17:56
24seven

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Post #15
you ned a GTi cat, but otherwise it'll go stright on if you can fit it in there. I've not tried to put mine on yet as I'm told its a head off job.

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Posted 21st Mar 2008 at 19:16
jcphat

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Post #16
I now have inlet and exhaust manifolds cat and down pipe on way. I am arranging for a set of 6 cams and a spare head to get ported and then my local friendly wrench-man will have a big swapsy day!!
I've learned a lot from these posts and would appreciate advice as to what components I will need. So far head gasket and manifold gaskets- some hoses not sure which? I will check whether the manifold complete with fittings has rail and check stepper. Anything I've missed?
Let me know!
I will tell everyone whether and how it works out!

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Posted 21st Mar 2008 at 20:09
birk

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Post #17
To put the exhaust manifold on, you have to take the engine mounts off, pull the engine forward, try and hold it forward some how, maybe a wedge, then try and put the manifold on.

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Dan
Posted 21st Mar 2008 at 20:17
gti6loon

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Post #18
birk wrote:
To put the exhaust manifold on, you have to take the engine mounts off, pull the engine forward, try and hold it forward some how, maybe a wedge, then try and put the manifold on.


Hmm..thats a big ask. Do you think you would actually get enough room to slide it down the back of the engine, even with the engine mounts off? im looking at a 6 manifold sitting on my kitchen floor right now and its pretty bulky.
You can call me crazyCrazy but im of the opinion that it would actually be less hassle to take the front end off, remove the drive shafts and lift the engine and gearbox out to change the exhaust manifold. Splitting the head is a bit of a pain in the ass, as IMO you should always have the head skimmed when its off, then theres having to run it in afterwards.
Whereas lifting out the engine complete probably requires about the same amount of mucking about with wires and cooling hoses as doing the head, and you also get the added bonus of getting to change the timing belt with plently of visibility and elbow room, and no cuts on the back of your hands.

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Posted 19th Apr 2008 at 06:18
jcphat

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Post #19
Exhaust manifold and cat pipe going on on friday night next week-Tim, "the wrench" is confident and thinks it will go with some wrestling. my other car may be useful over the weekend.....
He is working in his time but his employers shop/lift etc. I will be at hand to buy Red Bull and pizza!!!

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Posted 19th Apr 2008 at 06:26
mr swampy s16

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Post #20
Drop the subframe and put it in from the bottom.
Thats how i got the one in on my s16.only to find it wouldnt let the lower mount line up,the ports were different and it was far too close to water pipes for my likeing.
I took it all off and sold it.
Id wrap it,the zorst manifold that is,will help keep bay temps down and protect the hoses
Posted 19th Apr 2008 at 19:03
miles

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Post #21
As said the 6 exhaust manifolds fit with ease with the subframe off, you may need to adjust the rear water dist pipes depending on there routing

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Posted 20th Apr 2008 at 02:13
*arctic*

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Post #22
you will need to remap or change you injectors to work properly with the intake manifold. your engine will "suck" much more air with it ! here in Brazil we have many 1.8 16v with this swap. Gti-6 cams do a great job to !

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Posted 20th Apr 2008 at 08:55
m22tys

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Post #23
Otherwise, you could save your money and buy a 6 instead Smile
Posted 20th Apr 2008 at 16:31
welshpug!

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Post #24
6 is too fat compared to a nice 1.8 XS though Wink

if you want to see the power and ultimately torque you can get from these engines read Dixon's thread about the engine that Sandy has built for his race car.

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Posted 20th Apr 2008 at 16:40
marc l

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Post #25
welshpug! wrote:
6 is too fat compared to a nice 1.8 XS though Wink

if you want to see the power and ultimately torque you can get from these engines read Dixon's thread about the engine that Sandy has built for his race car.


Where's that thread? Mellow

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2001 BLACK Phase 3 XS - Sold April 2010
1999 WHITE Phase 3 GTi6 Big grin
1991 Peugeot 205 1.6 GTi - Track Car


Posted 20th Apr 2008 at 22:25

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