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Rowan

[Engine_Work] Not A 205, Other Frenchie. Rowan's Saxo 1.6 16V Turb

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Rowan

I'll post up my project thread here, even though it's not a 205.

I'm still working on it, so any remarks/comments/advice is greatly appreciated.

First I started collecting parts

Mocal oil cooler
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JP4 camcovers
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Megane 225 injectors (390cc)
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Uprated gear links
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Intercooler, oil catchcan, slim fan and 200CP sportcat
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Vems 3.6 standalone with wideband lambda and on board MAP sensor
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Re-looming the bugger
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And redesigned the woofer case to hold the 79Ah battery
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(will post more fotos when it is upholstered)

boost control solenoid
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MSD ignition thanks to trackdayparts.nl
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Got a crappy 16v lump for the rebuild. And while I was at it, got me a hoist and an engine stand.

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All the nuts & bolts are being replaced by stainless ones.
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New stainless 2.5" mufflers and flex part
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New valves, valve seats, seals, skimmed and vacuumtested
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Freshly honed block
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Since the block and head were ultrasonicly cleaned they could use a fresh coat of paint
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I've sanblasted some bits in the workshop at our service department.
The mechanics there were curious as always to see a pencil pusher getting his hands dirty :hug:
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Rowan

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Genuine HKS SSQV 4, order at an offical HKS dealer

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Clutchkit from the friendly and helpful Clutch-Specialists

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And the Tial MV-S wastegate from DP-Engineering

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Stainless for various brackets and such

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But more of notice, I've finally started with the actual build!

Baked myself an oilpan :P

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Ready to get cracking

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Fitted fan and string-fitted intercooler

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Interior gone and loom ready for sorting out

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Out with the old

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Enginebay ready for cleaning and painting

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The garage at the moment

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Rowan
  • 20130726_162540_zps1e5fd22d.jpg

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  • New track rods and link rods

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    f***ed bushes, so replaced them with powerflex

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    Refurbished the strut

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    Started welding

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    Figured out the wastegate runner

    The welds aren't the prettiest but they'll do the job, quite content with them since I'm just a desk monkey :P

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Rowan

welded up the bad boy

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Yes I wrapped the alternator cover and dipstick in heat reflective film.

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Old firmware

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Updated to latest firmware

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It is a bit overwhelming as a first time dealing with this sort of thing.
But it's just another challenge

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Henry 1.9GTi

nice! very nice.

 

watch out for the megane injectors. I had to replace mine at just 30k miles.

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Rowan

Cheers!

 

Thanks for the heads up!

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Rowan

What do you want to learn? :P

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welshpug

poor little gearbox!

  • Like 2

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rallyeash

Fair play. Impressive build. Indeed poor gearbox! You looking at going BE4?

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Rowan

Mechanical sympathy will be key for a while.

I still have a spare box I can throw on, but I will be looking into a BE4 (waiting for the Constella to come up with a kit for a level engine)

However, since buget is tight from now on (bought a house) it will take some saving to begin the conversion.

 

Is there anyone on this forum who has experience with Vems? I'm trying to get a base map set up and could use some pointers/advice.

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welshpug

looking at the fabrication skills you have, you wont have any trouble making the BE4 conversion yourself, no need to buy stuff.

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td_dan

really stunning and such attention to detail look forward to more updates

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calvinhorse

Top work, looking really good!

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2052NV

wicked! I love lots of photos!

Edited by 2052NV

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Rowan

Thank you all!

 

And I'll post a topic in that section :)

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Crocksy

very well done mate! :)

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Rowan
A wee update.


When it first started it didn't idle and the 4th cilinder wasn't really puttin as much effort into it as the other 3.


Hence I decided to clean the injectors and sparkplugs. Altered some bits in the Vems and started it up.


All 4 cilinders purring and it even idled! (at +/-1200 rpm and only when warm :P)


And so the first test around the block came to be :oops:

Even though it's not as smooth as it could be, it already is a huge difference.

I've set the wastegate to .5 bar boost for safety reasons, since it's not really mapped.


This also means that de screamer pipe comes in really fast, and that sound is just pure porn. Which is followed by the HKS bov, and I feel like a little kid again :P


New tires are being fitted as we speak, then it's of get aligned and the wait for the 1st october when it is getting mapped bij Pieter at DP-Engineering.


A few pics to round it off.


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Rowan
Teaser:


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(not dyno'd, running on a safe basemap)

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Rowan
After a long day tinkering, mapping and testing a result has been achieved to my satisfaction. Again, I'm not in it for the numbers, for me it's about the driveability and fun (building and driving)


195HP en 270NM @ 0.65 bar


That was all we could get out of the tiny T2 turbo, however I''m very pleased with the result. The power is right where I use it and maybe the chocolate MA box will last a while now.


The drive home from DP-Engineering put a smile on my face from ear to ear :)

Even got to test how it holds up in traffic :homme: Temperature just above middle in the gauge. The clutch is some getting used to, but works very well.



Very pleased with DP-Engineering (Pieter), excellent service!


When I arrived we sat down for coffee and had a chat about my build and other related stuff. Then went to check everything and came across the stepper (iac) which didn't cooperate. After we've been upside down in the car checking the wiring from the vems behind the dash we came to the conclusion some wires have been switched around (my bad). Fixed it and Pieter started the mapping.


After a few minutes Pieter said the standard iat sensor was too "slow", which would affect enrichment and timing in a negative way. So off with the boost piping and het welded up a bung for the new "fast" sensor.


Anyway, after all this tinkering we were a few hours in before the real mapping could finally start. He was working his magic and we came to a good result.


Pieter was impressed with my driveway-build but expected a bigger turbo when he saw the engine with external wastegate, boost controller, etc.

He recommended a TD04 for more breathing room and performance (whilst still on a budget).


For now I'll just enjoy driving the thing and fixing a few minor things


And the pics:


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2052NV

Thats awesome must be a blast to drive!

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2052NV

Also how awesome does the wastegate sound??

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