stef's 205 gti6 supercharged

[Stef205]

So mot didnt go to plan, map sensor shit its self on the way over and told the ecu to continually fuel for wot which made driving nearly impossible! I did a few wiring tests prior to ordering a new one. So a new 3 bar sensor ordered and £90 down

[Ruan]

£90 for a 3bar MAP sensor!?!?!?

[Stef205]

afraid so genuine omex only

[Niall]

Genuine Omex? Dude Omex don't make them. It will be magneitti Marerelli (sp?). Could get much cheaper elsewhere!

[fatlapit]

doesn't have to be an omex sensor I uses a 2.5 bar mm one that's from a lancia/cosworth and as niall said omex don't even make them.

[Stef205]

My bad next time I'll consult the experts first next time.

[Stef205]

So this year i had to use a new mot tester due to my normal tester being away. Decided to use the station down the road from work purely for convenience and im not charged, Easy right?! NO! Half way though the test he moves on to the emissions and asks me to hold the revs at 2.5/3k? i asked why he said it needs to pass a cat test!! Straight away i think WTF! Bloke is a tool! Anyway after driving a few choice words into him i come away with no ticket and he fails the car on that i refused a emission test! Get back to base and tell the tail. So i knew i was right in saying the car only needs a idle test at or below 3.5% co. Anyway i print off documentation to prove i was correct and show the tester, i get a phone call from the owner to say to bring it down tuesday and they will test it again at 3.5% as it should be. What a ball ache for no reason! 

In other news the car recently had some running issues, One was traced down to a slipped exhaust cam vernier! Timed engine back up correctly cleaning the threads on the vernier bolt and threadlocking the bugger. Save to say i was lucky! no damage
Second issue was traced down to a loose crimp terminal in the main plug on the ecu on the 5v and sensor earth wires so just the main ones Dab of solder on the terminal sorted that.

Recently the pot pump has been getting extremely loud i investigated it and found the intank pump is pressurizing the pot and the return not big enough to reduce this, Changing the return for a bigger line isnt a option to me so ive opted for a low pressure feeder pump for the tank which will give 5psi at most but its only to fill the pot doesnt need to keep up with the engines demand.

Ive just about had enough this week with the car! But i dont believe in giving up so i did some parts shopping and bought my new injectors, talked manifolds with my friend and booked in with sandy for a tune up. 

Stef

[fatlapit]

Im no expert but it aint rocket science

[Stef205]

what isnt?

[fatlapit]

The sensors

[Stef205]

dude do your self a favour and dont talk to me please and stay off my thread you never have anything nice to say about others.

[Piggy]

Chin up mate.
You have one of the most epic fwd 205s I know...
Cant wait to see this at fcs!

[Stef205]

Been playing with fuel lately, Firstly after the mot my new 044 pump went faulty after a few miles extremely loud and pulsing fuel pressuring. Fitted the replacement but found my in tank pump was pressurizing the swirl pot so i sourced a high flowing feeder pump with a low pressure rating.



Fitting it was nearly criminal going from the bigger and fastest in tank pump to the slowest  needs must! After fitting the pot seems much happier.

Next i had some goodies arrive

The new injectors!



They are the lastest bosch ev6 model 470cc @3bar So plenty of fuel if needed. I didnt choose these because they give lots of fuel or that im chasing more power or unicorns! but mainly down to their spray and efficiency.



Even better than they are standard height which means no rail modifications needed.

Heres a comparison of my current lucas red bands 380cc vs the new.



As you can see they are already going to be far far better than the current ones.
I did a bench test of spray patterns not only to satisfy my self but to see how the injectors need to be positioned in the inlet for optimal performance. I was pretty shocked at the results and if you think these lucas items are bad you should see the favored Bosch 804 greens! :O



Lucas 380cc's on the left, New bosch ev6's on the right.

All for now

Stef

[welshpug]

cool, those lucas off a rover turbo or similar?

[Stef205]

yeah they are tomcat turbo i bought them when i first started out years ago now 4 brand new at £70 so i jumped.

[Stef205]

Been out putting some miles on the 205 lately finally enjoying the non surging fuel system! Ran into a issue one afternoon where id lost all power and nearly no boost what so ever. Found it very odd, check with the laptop all seemed well. Opened the bonnet to find this.



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Supercharger said nom nom close call imo Turns out the charger isnt fond of filters and having removed the filter boost levels have gone up. With that i will be speaking to ITG tomorrow about one of there nice air boxes as much as a open charger inlet sounds its risky. I have already made way for a air box including making the less important things smaller and moving them.

[url=http://s10.photobucket.com/user/skyline_999/media/205%20gti%20project/9EA2D58B-8EC4-46E2-B8B6-093E57F0BEBA_zpsn4cl27my.jpg.html]

But apart from that i LOVE the open inlet haha. Lately we have been leaning on the poor engine abit more slowly turning it up and now i have the fuel system to deal with it.

Sunday i attended the Bhp fuelfest show as it is very local to me, Cued for over a hour and a half wasnt happy nor was the engine had to pull out the line as the car couldnt deal with it and wasnt worth it. 30mins later we cued up again but used a lane that wasnt being used and jumped to the front haha.

Anyway parked up with the other half created a crowd nearly all day with lots of questions including if it was for sale.





All in all a good day.

I have booked the car back in with the wizard to mainly check over things, like him to do it every few years even if its a tweak and to map the new injectors in.

Stef

[insomaniac45]

Wow fella, she looks beautiful. Lucky on that filter, could it be because it's a soft filter and not a hard case one, some only have the case on the outer, which are useless when using booooost, but ones that are fully meshed up should be ok

[Dum-Dum]

That really is a great picture showing the difference between the spray patterns.

[Stef205]

Wow fella, she looks beautiful. Lucky on that filter, could it be because it's a soft filter and not a hard case one, some only have the case on the outer, which are useless when using booooost, but ones that are fully meshed up should be ok

Ive used many filters including the hard lined one the restrict the air flow to the charger causing loss of power and boost, the sock was the least restrictive, Ive been on the phone this morning with itg and we have come up with a idea so will see how it goes.

That really is a great picture showing the difference between the spray patterns.

Huge difference really when it lands in the cylinders, pattern will be better in the car as the test was done straight off the pump at around 5-6bar.

[Stef205]

Few pictures from fastcar at french car show
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[url=http://s10.photobucket.com/user/skyline_999/media/205%20gti%20project/racepak_zpszaq9wq0r.png.html]

Coming soon

[Stef205]

Visited the rollers today with sandy, Made some noise and some power then went home



https://www.youtube.com/watch?v=O5vxQna1NQ8

Stef

[welshpug]

what's the wheel numbers there? do you struggle for traction?

[Stef205]

No idea for numbers, sometimes I struggle better now with the plate diff in.

[welshpug]

I struggled on the rollers with my old engine which was quite mild, hoping to be down there again soon with a fresh build.

[Stef205]

yeah we had real bad spinning issues to the point where it would spin then grip again making the engine stall at times alot of traction fluid and was all well.

[Stef205]

Pugfest:-

Drive up was good, I filled up with texeco 97 around £40/45 Just over a 2hr drive mainly M5 driving sitting at 80mph @4k 1/4 used which was good!

Sat camping was fun and entertaining although camping next to you lot was a mistake Caught up with a few people which is always good.

Show day i parked up in the pscuk area for the first time which made a change. Car performed well although my rear shocks were limiting me in the corners. Already in talks for a decent coilover setup and swapping out my 22mm and 25mm bars for some thing bigger. Was nice to corner harder without horrific fuel surge! Did 4 runs and used 1/2 tank!



Thanks to tom for this shot! :




Return trip was perfect and got home on 1/4 tank which is brilliant around 32mpg.

Stef

[Stef205]

New clutch,
I had it made by a local company i sent them a fairly new luk unit and they do various work to turn it into a 4 paddle unit. The pressure plate has been machined and springs toughened up as with the friction plate. Same spec as colin satchel used for awhile Will give it ago but i plan to buy a new flywheel first.



Atm the engine knocks off new clutches after about 4k and suffers with heat and slippage, cant let it off anymore otherwise reverse wont be a option.

Stef

[Frosty]

Where abouts did you get the clutch made if you don't mind me asking as you say it was local?

[Stef205]

Dpr clutch services, lifton

[PocketFighter]

I've just sat here for the last couple hours reading pretty much the entire thread...

craftsmanship, patience and art...

what a build mate!