1990 205 Gti 2.0 8V Turbo Conversion (Xu10J2Te)

[lemmingzappa 75 1 Cars]

Time to fit this new solid fork mount, don't have access to a press or removal tools so I went ahead and used a 30mm hole saw and then pushed the new one in with some grease and a vice.

 

 

The SRi/BX box I'm using had a selector arm fitted which I wouldn't be able to use. Drove the pin out using a punch and pulled the old arm away, be sure to have the box upside down at this point so nothing falls inside.

 

 

Correct arm taken from another GTi BE3 box now fitted.

 

New genuine plugs and speedo drive seal for the box. Not sure if I will be using the reverse switch yet.

 

Removed the old drive shaft seal (PITA, wish I knew a quicker and cleaner way of removing these).

 

 

New seal fitted!

 

Time to swap the speed sensor over to the 3-pin dual type. I first removed the speedo drive cog from the existing setup.

 

Then pushed into the new dual unit.

 

Ready to go!

 

Got myself a brand new genuine VAG '710N' recirc valve. The latest version to date is the '710P' which is used on the Audi RS6, but these are unable to hold boost as well as the N versions.

 

Next I noticed this ring on the end of the crank, wasn't sure if the BE3 input shaft would fit inside this. Possible only something found on the auto turbo blocks.

 

Definitely not, as the input shaft is around 15mm.

 

Luckily these are easy to remove with a screwdriver as they are made of plastic!

 

Went to fit the clutch and pressure plate and made the silly mistake of over-tightening the bolts, which then sheared off inside the flywheel.

 

Luckily I was able to remove this by drilling a 3mm pilot hole and hammered a 4mm allen key in, then remove by hand.

[Slo 283 1 Cars]

pain in the fkin ass them flywheel bolts i popped 3 tightening mine up they feel so loose then doof.

 

how much was the plastic dump valve, farmer got me a new original unit out of thin air, they work so much better than after market crap

[lemmingzappa 75 1 Cars]

pain in the fkin ass them flywheel bolts i popped 3 tightening mine up they feel so loose then doof.

 

how much was the plastic dump valve, farmer got me a new original unit out of thin air, they work so much better than after market crap

Yea that's the same feeling I got when tightening.

 

I got the recirc for £25 delivered from Germany.

[estland 3]

Very cool project. Looking forward for an update

[lemmingzappa 75 1 Cars]

Final coolant plumbing diagram.

 

63mm > 60mm reducer (turbo to intake pipework) & high tensile m7 bolts for the clutch cover.

 

The plan is to run this on the intake pipework to dump the recirc'd air back in, near the turbo.

 

FPR blue vacuum. I'll get round to the other vac hoses once the engine is in the car.

 

This bracket on the dipstick tube holds the oil filler tower in place. Unfortunately the lower silicone hose now catches on this as it's thicker than the original pipework.

 

Easy to resolve with some cutting and smoothing, using a dremel. Then touched up with black paint to protect the metal.

 

Got round to configuring the VEMS 'Round' AFR/EGT gauge. I won't be using the narrowband output until I run aftermarket management. AFR showing between 14-15 when holding in the tailpipe of another car, so I'm fairly confident it will read ok.

 

Configuring the EGT sensor using ice and boiling water. I'm now seeing 100 degrees between the two and will need to use the correct offset to show 0 on ice.

 

Figured out my ideal calibration (specific to each sensor and gauge). Burn to ECU!

[Kezzer30 40 1 Cars]

Looking at this with interest as I wanted to do this for my next project but being told the wiring is an absolute pain to sort etc .

[Daviewonder 533 3 Cars]

Looking at this with interest as I wanted to do this for my next project but being told the wiring is an absolute pain to sort etc .

 

Wiring is probably one of the easiest parts of the conversion.

[Slo 283 1 Cars]

Wiring is probably one of the easiest parts of the conversion.

Having been at this point myself i agree its really simple once you have worked out which wires you dont need rather than what you do need, that said having wire numbers and a diagram to work from makes it even simpler but mine is the old style management and needs the keypad plugged in it wont run without it

[johniban 59 1 Cars]

Really like this project, nice attention to detail

[estland 3]

Any progress?

[Anthony 1,000]

Its all in the car largely ready to go and looking pretty good... other than the wiring loom which is currently spread over my living room floor while I finish off converting it for him.

 

Those saying it was easy I'm assuming didn't start with an XM loom. The basic connections to make it work in a 205 are easy enough, but nothing is in the right place for fitting into a 205 (atleast how Josh has done it anyway) and needs relocating/lengthening/shortening to fit. Its an utter ballache to do nicely compared to Mi16 and GTi6 looms IMO!

 

Still, he'll have it back this month as his Xmas present

[lemmingzappa 75 1 Cars]

I ran out of free time to keep this thread up to date unfortunately but as Ant has said it's pretty much ready to go, just a few small bits here and there remain. Very much looking forward to receiving the loom and giving the key that first turn!

 

Will be without an exhaust to begin with, but I'll be happy to get it started to be honest. I'll post vids/pics once that happens.

[Anthony 1,000]

Will be without an exhaust to begin with, but I'll be happy to get it started to be honest.

I suspect that your neighbours won't be quite so happy...

[Miles 331 1 Cars]

Looking good, not read it all but the speedo will be out with a black gear on the pick up, should be white/cream and red

[lemmingzappa 75 1 Cars]

Looking good, not read it all but the speedo will be out with a black gear on the pick up, should be white/cream and red

Thanks for letting me know. The black one was removed from my 1.6 box, I presume I need to source a red gear from a 1.9 unit?

[welshpug 1,621]

1.6 should have a red cog too.

[lemmingzappa 75 1 Cars]

1.6 should have a red cog too.

 

Gosh, I guess I've been using the wrong one throughout my entire 205 ownership then. Any idea where the black ones come from?

[welshpug 1,621]

306's iirc

[lemmingzappa 75 1 Cars]

.

Edited December 12, 2015 by lemmingzappa

[lemmingzappa 75 1 Cars]

Ok so over a week ago the car had its first proper start, no exhaust fitted as of yet but that is due very soon! Seems happy enough idling & revving a small amount,

Hope to have it MOT'd this month, providing I can stop my brake flares leaking.

 

Huge thanks to Ant for the loom conversion! More videos to come.

 

[j_turnell 134 3 Cars]

Happy days, looks like a tidy install too, good work.

[lemmingzappa 75 1 Cars]

[jackherer 543]

Excellent, just need some dry roads now

[lemmingzappa 75 1 Cars]

Bring on summer!

[Slo 283 1 Cars]

You wont be saying that when you see the temp go up lol. Looking good zappa whats your 0-60 time it should be around 6 seconds