[engine_work] The Black And White Pug Project

[Goliath 94]

Hi, i have decided to start my own project after being so inspired by all the cars in the project section! I have never done an engine conversion before but am confident that i will find all the info and help i need from all of you also im willing to give (almost) anything a try once, so here goes!

 

My plans;

2.0 turbo engine conversion (from 605)

contemplating using 4x4 from an mi4x4, i have read all the topics/debates on here about the 4x4 strength and so on and have decided to only use it if i can get it strengthened sufficiently.

Roland garros interior.

Painted black on the outside and white under the bonnet.

 

I intent to do it in 2 phases, 1) Do the engine conversion and get it running, and 2) Make all the exterior and interior look nice!

I will put the best/most interesting photos on here but all of them will be going in my photobucket album HERE

Deadline is pugfest 08 for phase 1 (dont know how realistic that is!)

 

Anyway, on with the project, i sourced a shell from kevp so went to pick that up a couple of weeks back

I am very happy with it as every panel is straight apart from a little stone dent above the n/s rear wheel arch. I got straight to stripping down the engine bay ready for its white paint

And i took off the subframe and have taken it back to the metal and resprayed it

 

More updates as soon as i can, i work on it pretty much every day so should see frequent updates.

Im going to pick up the engine on friday but for now am going to carry on stripping/sanding the engine bay, not much rust to deal with so im happy

[Pug_Power_Dave 0]

Good luck with it man! look forward to the updates! Shell does look real tidy and the sub frames come up a treat!

[felix2566 2]

Looking good, seems like there are more and more Pugs turning up around gloucester, Brilliant!

Loving the fresh subframe!!

[j_turnell 134 3 Cars]

Interesting project although i would use a different 4x4 system if i was you. The 4x4 rear axel weighs a huge amount, you'd need more than 150bhp to shift that along quickly. Also the transfer boxes are pretty weak. Plus there are huge amounts of work involved such as turreting the rear suspension, bigger tunnel and using the subframe from a 405 up front.

[Goliath 94]

i would use a different 4x4 system if i was you.

What system would you suggest? I am going to make it run just FWD first and then consider my options, although i have the 4x4 system so will still be putting up pics of the overhaul!

like so...

The 4x4 system I got from Pug_power_dave

After a little tidy up and a trial paint on one bit..

 

Also i got some 'two tone' paint today just because....

it might be good when done properly (i just did it quick'n'crap to see vague results!) but im not too impressed tbh

Only painted the middle bit of the wing.

 

More updates tomorow but for now bed and then a long night shift!

[hexhamstu 9]

dont you dare put 2 tone paint on that pug

[AdamVester 0]

*~SLAP~* dont 2 tone it!!!

[Goliath 94]

dont you dare put 2 tone paint on that pug

 

 

*~SLAP~* dont 2 tone it!!!

 

calm down! i wont be painting it two tone, was just a passing thought! I think if it was painted professionally with a nice two tone colour combination it would look good though.

Today i have put the first coat of primer on the engine bay and front end after kurust-ing it, I will get some pictures up tomorow, also i am picking up the engine tomorow so its all progressing rather nicely

[applemobile 0]

why not go rear wheel drive? maybe an old escort axle?

[welshpug 1,627]

live axle?! stick with the 4bie stuff! independent suspension rules

[swordfish210 20]

at the Escort axle, live axles were crap when they came out and they're crap now

[Goliath 94]

A quick update...

I was due to go and pick up the engine on friday but hadnt managed to get the towbar fitted so instead of letting the chap down i went along anyway and thought i would just bung it in the boot............. maybe not such a good idea as the suspension didnt like it, although its fine now!

Very low!

Managed to heave it out the other end with the help of a winch

 

Also done a second coat of primer on the engine bay, pictures are naf as the sunlight was bright and its a phone camera!

All coming together nicely so far although i feel its going to get complicated very quickly as i dont know much about engine conversions!

I am trying to source the correct engine mounts at the moment and im not sure what to do with the loom as i only have the engine loom and not the whole loom?! hmm

should be able to get some more done tomorow............

[M_R_205 5 1 Cars]

What you need is throttle bodies and a mapable ECU a turbo conversion with a twist

 

Looking good mind!! you should paint the bay matte black looks well cool

[Goliath 94]

Not updated in a while as i have only got small bits done really (due to work i only get every other weekend off), finished painting the engine bay, will be getting some new rubber mounts and top arm next week so will hopefully get the engine in within the next couple of weeks. also got new drop links on the way and have put the refurbed subframe and wishbones back on and its looking goood! Got some bilsteins now too so they will be going on after a little bit of a clean.

Pictures to follow.....

[Goliath 94]

I have tried to put the engine in today but it dosent fit! so i need some answers if possible... I have the correct top engine mount and have got that on fine but its the gearbox mount is the one that wont fit. Its about an inch too far to the nearside, as if the engine is too wide. I still have the gearbox that came with the engine on there but i thought that was the same size as a 1.9 box?

Iv got someone coming to pick up the car at the weekend so i really need it done today!

thanks

[tom_m 0]

I have tried to put the engine in today but it dosent fit! so i need some answers if possible... I have the correct top engine mount and have got that on fine but its the gearbox mount is the one that wont fit. Its about an inch too far to the nearside, as if the engine is too wide. I still have the gearbox that came with the engine on there but i thought that was the same size as a 1.9 box?

Iv got someone coming to pick up the car at the weekend so i really need it done today!

thanks

 

no the ml gearbox is huge and defo won't fit. you need to swap to a BE box to get it in.

[sonofsam 5]

no the ml gearbox is huge and defo won't fit. you need to swap to a BE box to get it in.

 

 

and a 215mm flywheel to get the 'box on the engine.

[Goliath 94]

Cheers guys thanks for that, at least i wasnt missing something blindingly obvious when trying to cram it in how it is!

 

next question.........

 

My next job will be the wiring, now how is best to go about this with the looms i have? I have the full 1.9 loom and ecu still in the car, i also have the turbo engine loom and ecu (no idea if its unlocked). I was going to try using the 1.9 loom but modify it using the turbo loom where neccessary ( as i believe the 1.9 one has most if not all the wires needed but just different connectors on the end) and then i was going to plug the turbo ecu into the slot that the 1.9 ecu is in, any idea if it will fit or is it completely different?

 

Would this be a good way to go about it?

[inferno 1]

Been covered loads of times in the turbo projects, you remove the gti ecu and loom attached (leaving the brown multiplugs part of the loom in the car) and fit the engine loom from the turbo engine. Ive always used citroen engines and i know color coding varies, so some of the other guys would be more usefull than me for wiring questions, but im pretty sure the diagrams are online on the forum now. I normally just wire from memory, at the brown double relay, and the black citroen only immobiliser plug to bypass imobilisers, but the pug may be a transponder.

 

Good luck.

[sonofsam 5]

as said discussed many times over, atleast 15 pages on the search

 

http://forum.205gtidrivers.com/index.php?s...hl=turbo+wiring

[Ant 2]

If the lump and ecu came from the 605 as you said in the earlier posts, it will have a keypad. 605 ecus can be unlocked by a switched live feed to pin 27 of the ecu ( wire 32a i think ) from the keypad. so wiring should be easy. Do a search as i covered the 605 wiring about a year ago. should be similar for yours

[danpug 1]

Are you still going for a roland garros interior? If you are i may have one available.

[Goliath 94]

thanks for the offer but this project has been sold now (picked up this morning) sold to a guy called paul from kent, he will be using it as a track car primarily although he will be making it road legal.