Project Daily Sigma (16V TU)

[darrenjlobb]

Then the "management" loom on the engine, with all the "tails" hanging off the table ready to splice into oem loom:



Tidied:



Then dropped the motor in the car, had to modify the engine mount somewhat, and use bits from each motor, but fairly painless being the same block down below. main issues with mount was literally just cambelt clearance / cylinder head clearance. Looks happy in there:






Next issue to resolve was fuel lines, for some funky reason (anyone know why other than to save running two lines??) the 8v on the 306 only has a single fuel line to the engine bay, and runs the pressure regulator under the rear seat, which was an issue as the vts motor has a more conventional setup with the pressure reg on the back of the fuel rail, so i just sacked off the rear regulator, ran a new fuel host front to rear (clips right into oem clips) and that sorted that out:





Few modifications needed to throttle cable, but again, nothing serious.

Then started on the exhaust, using a stock saxo downpipe, in this case an aftermarket 4-2-1, it bolts right on, but terminates about 2-3mm away from the subframe, leaving no options on pipe routing, so decided to shorten it up to give me some space to work, and then weld a flange on the end so that I could bolt on a "up and over" pipe to go around the subframe thats in the way on the 306.

Bits of pipe i started with:




Chopped collector up to shorted it up:



The rough idea:




Might be worth noting at this point, please ignore the HORRIFIC attempt at welding that the PREVIOUS owner of this manifold has done!!!


Welded up:



Welding flange onto "up and over " pipe:



OEM lambda sensor fouls the sump, so bunged it, and drilled a new one:





In situ:



Support bracket under engine (to stop weight of exhaust flexing manifold):



Up and over in place:



Then started on the exhaust itself, basically used a stock downpipe, (aftermarket one with bigger bore) then bits and pieces to make up a full system of 2 1/4" bore.

Welded a D turbo flange on the end to mate with the new "up and over" pipe i just made:



Changed rear bumper for one with cutout (sadly not exact colour match as its from a phase 1 sigma, and this is a rather rare ph2 sigma), anyway all i had so mounted it / welded some exhaust mounts on and got that fitted up:



And all in, after quick test drive:




Had to modify the gear linkages (cut a section out the selector arm, and shorten the "long" rod. Having a missfire issue under load, but 99% sure its the coilpack, typical coil over plug, seems fine when cold, but gets worse and worse as it heats up, so have ordered a Ford coilpack and some HT leads to relocate that , so hopefully then it should be up and running.

Also worth noting, air filter is a temporary bodge Will locate it in the wing in front the battery asap, but need to find some OEM looking black hose first!

I know its likely to attract the old typical "why bother and not just mount a gti6 motor", well mainly just because I like to try things that are different, and tbh, I can genuinely say i preferred driving the stock 8v over a gti6, and this even with a bad coil pack has shown me that it still retains the super lively TU feel, with more power, the love is with Derv, but it has to be said, this car is yet to let me down, so credit to it (cough petrol cough) for that, hopefully this will keep it going for some time yet!

Videos of the conversion,

Part 1:



Part 2:



Thanks for reading/watching