205 Cti T16

[GT3071R 5]

Hi,

 

In this topic I will start my new project...

 

In basic my 205 CTI which first was fitted with a MI16 with Lysholm compressor.

I sold the compressor set-up some years ago and the car was just stored in a garage.. waiting for...

 

Waiting for This....

 

The car on his way to get totally stripped:

 

 

 

 

What a mess

[GT3071R 5]

And the engine started as:

 

 

 

 

S16 head

Cometic

S16 engine

Wiseco T16 forged pistons

K1 T16 forged rods

T16 forged crankshaft

[GT3071R 5]

The brakes:

 

I like to drive with 15" rims, specialy the Sl434 or SL431 and R888 tyres.

So more then a year ago I bought some Megane RS calipers.

 

To fit the 302mm discs.

 

Test fitting

[GT3071R 5]

 

 

 

And fitted with 17" rims it's like this:

 

[GT3071R 5]

The I started to do some work on the engine:

 

Preparation to measure the CR on a later state in the assembling process...

 

 

Modify to change the original coils to a set from Audi

 

With a little modification to the cap the will fit:

 

You see...

 

And now the fit!

 

 

Case closed:

 

[GT3071R 5]

So the inlet manifold...

 

Original on a 306 GTI-6 or xsara....

 

Did some little changes.

 

Exhaust manifold from DP-engineering

With ceramic coating

 

[welshpug 1,622]

not quite sure why you went from one coil known to break down with 100k miles and a bit of heat, to another coil that is even more renowned for breaking down and causing no spark?

[GT3071R 5]

Rods,

 

What happens when you put XU10J4R or RS bearings in a XU10J4TE rod:

 

 

 

XU10J4R bearings are 20mm

 

XU10J4TE bearings are almost 22mm.

 

 

 

Better fit I think:

 

[GT3071R 5]

I have no picture of measuring the piston to wall clearance.

But offcourse its done...

 

Then it was time to make the ring clearance confrom spec:

Top ring 0,43mm

Second ring 0,475mm

 

Checking the big end and main bearing clearance:

 

 

[GT3071R 5]

Fighting with the clips...

 

 

The result

 

 

After this I could calculate the CR:

In dutch

Dikte koppakking: 1,3mm

Dekhoogte: 0,75mm

 

slag volume: 505cc

kop volume: 37cc

zuiger volume: 14cc

pakking volume: 7,5cc

dek volume: 4,3cc

 

CR van 1:9,05

[GT3071R 5]

To keep the coils cool and due to the very good experience with this mod I made some vents in the coil cover:

 

 

New layer of powder coating:

 

[GT3071R 5]

Oil pump:

 

I used the XU10J2TE/XU10J4TE oil pump instead of the XU10J4R.

The size difference is huge.

 

So I had to make a little modification to the... (What is the name for this thing?)

 

And to have another 1 Liter of oil capacity I put the spacer in between from the XU9JAZ

 

 

And checking the distance for the oil pickup:

 

[GT3071R 5]

Putting it all together:

 

 

 

Finally I made a complete new wiring harness..

 

It was realy a lot of work! I used new (automotive spec)wires, new contacts etc..

The only parts a re-used are the connectors, because of the different colors so the match the original contra's.

 

[GT3071R 5]

In the spare time I found a set of the Recaro A8 seats in good and original condition. (A lot of them have the back panels painted).

 

The are very light weighted even the are electric.

Yes I know, the need a nice re-trim to match the car.

 

[GT3071R 5]

The the car it self... I just put all the pictures in.. without writting anything down.

 

 

 

 

 

 

 

 

 

[GT3071R 5]

 

 

 

 

[jord294 87]

nice work mate

[gavbrum 18 1 Cars]

very nice

[pip470 61]

If i close my eyes and dream about the car i would want, then this is it. Great work. Its going to be a great car.

[Weser 30]

Ahh this is the car I would love to build. Maybe one day I can sell the Mrs, then I might beable to.

 

Its looking great, I will be following this!

[GT3071R 5]

Thanks guys!

 

It is a lot of work and a little expensive, but so nice to work on.

When it is finished I will visit Pugfest together with Kuuner and....

 

not quite sure why you went from one coil known to break down with 100k miles and a bit of heat, to another coil that is even more renowned for breaking down and causing no spark?

 

Is it? Do you refer to some practical examples?

 

We have other experience.

 

What I also did due to good experience of other XU10J4R drivers is the air vents in the coil cover.

So the will stay a bit cooler.

 

Regards,

 

Stefan

[GT3071R 5]

 

 

 

 

 

 

And back on her wheels with the RS brake calipers and 302mm discs mounted.

Not mentioned but also a Quaife is mounted in a BE3-6 gearbox (maybe not the perfect choice, but can be changed)

 

 

[lewis205cti 12]

Looking impressive. Nice to see a CTI getting a once over.

[aarontrophy 26]

The engine build looks fantastic )) have you had a thought how you are going to run your boost pipe from throttle body to inter cooler yet. Looking forward to seeing the pictures and write up

[Henry Yorke 269 3 Cars]

How come the majority of the most powerful 205's are Atlantic Blue CTIs with T16's in them and PTS wheels (Yours, Magics, Numero D'Or, not mine as it is a T8!)

 

Great stuff though. I will colour code my strut brace next time I get some parts painted.