205 junior xud

[randomcaller]

Then the conversion began. The lump going in was a dhy lump (yeah I know :/ ) with 62k on the clock, a/c which would be ripped out and power steering. It was a fairly straight forward swap with the odd niggle getting in the way. I had do space the main coolant pipe as it was too short and would pull against the turbo, the rad housing and fans had to go and brackets knocked up. I had to use the standard 1.8 box as I didn't get an xud box so swapped the fly and clutch over.

A new cam belt and water pump, along with tensioner and idler pullies were installed along with ripping off the a/c compressor and a nee aux belt.


It took a bit of persuasion to get in with the box on but I had help at this point and the heart transplant was nearly done.



Then at this point there was plumbing to be done and some wiring which I have no clue about but I have a friend who does looms for rally and race cars for a living so it was a very easy job for him. As I said earlier the rad was a bit strange to do with very tight clearance by the alternator and I had to buy a boost take off metal collar to plumb the heat exchanger into as the 205 rad only has one bottom inlet.

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Then after a few hickups, such as the immobilized pump and getting the fuel lines on the wrong way round and a leaky injector pipe as my mate said he had tightened it after he cracked it which he didn't! It was all living and breathing. I bought a 306 d turbo down pipe for 15 pound from Euro car parts and knocked up a cheap system using some spare pipe and the rest of the 205 system although it still touches on the gear linkages. I slapped a spare 57i that I had lying around on it and it was good to go.

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Since this I've bought some gti leather seats which I have given a good clean up but only have a pic from when they went in dirty.


I think I might keep the denim door cards and blue carpet as it looks pretty Pimp
I also replaced the tape player with a free head unit (keeping it all cheap!)

She then went for an mot and failed on a rottom subframe which I was going to stuff with kitchen towel and spray black but totally forgot about it lol so I had to replace that and bought a new one, sanded it all down, sprayed it and replaced all the bushes and then it passed.

Also I have replaced the gear linkages for some adjustable new ones and it feels much tighter now! I added a boost gauge and water temp gauge tool, I liked the look of the stack ones as they have more of a vintage feel to match the car I think.


The boost gauge here is just temporary as I want it where the clock is in the dash but I hear it's a pain in the arse ripping the dash out.

One last thing I did at the weekend was buy some 1.9 gti brakes with braided lines and vented discs and ferodo pads so now it stops a lot better and they just squeeze behind the 13 inch steels with a millimetre to clear!

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Nice, you staying with the standard turbo or going for something fun?

I think for now I'll keep the standard turbo as I've tweaked the pump and waste gate and it feels fairly nippy and when I was between tweaks it was level with my mates e39 525d up until 95 which isn't too bad! but my other car flies past it :p

Might opt for a larger turbo in the future, well I say might but I know I will do :/ but I'll upgrade to a Bosch pump then and make sure I get some forged rods to match as I've seen plenty of these engines throwing a leg out of bed!