Ok, i have been dabbling with the idea of building a 16v turbo engine for the past couple of years, this has stuttered

and stalled several times due not being able to decide on the best possible way to go, so once again im going to try

to see it through.

Parts i have stock piled:

Low miles XU10J4RS from a 2002 xsara vts
90k xantia 8v turbo lump
genuine 405 T16 exhaust manifold
Garrett T3 from sierra cossie
cossie Level 8 ecu, all its various sensors, injectors etc etc
Cossie throttle body
Quaiffe diff

My biggest problem is what bottom end do i build, various options,

1)use the 8v turbo bottom half, but mine has the later dished pistons so i would have to machine approx 0.8 - 1mm off

the face to allow valves to clear, however i'm not sure the deep dish will work in conjunction with 6 head. other

benefits of using this one is that it already has turbo oil feed and drain points.

2) use my complete gti6 bottom end and machine approx 1.8 mm off the pistons and use the thickest gasket i

can get.

3) again, use gti6 but with a Decompression plate from the likes of Ferriday engineering, but always worry about

the seal between plate and block.

i have also looked into sourcing and modifying C20LET pistons which share the same bore size and are factory forged

ideally i want to use the early 8v turbo flat top 8:1 pistons but cant find them anywhere, believe me, i have searched

high and low

I am very tempted to do the decomp plate thing but at the same time i think the 8v turbo bottom end would be the

way

to go, given that its a factory turbo uprated setup

Anyway next problem, i have done various dummy builds and when i fitted my T3 to the manifold, the exhaust

housing is too close to the head - no where near enough room for a downpipe. What i need is an Escort RST

exhaust housing (same A/R's as cossie t3) which is a far neater design and would give me a 5 bolt downpipe

pattern, i believe this is what Ecosse did/do to get around the problem

Also looking at TD04/05 turbos for scoobs/evos, these are very plentiful and are ideally suited for what im doing

Management wise i'm looking to use a sierra cossie L8 ecu with a wasted spark conversion as the 6 obviously

doesnt have a distributor! Basically i need to solder a Wasted spark driver to the cossie ecu then run 2 ignition

amplifiers along with a 8v turbo coil pack and leads, coil will be fixed to end of head via 5mm ally plate

I personally know of someone who has done this and it works very very well, plus when Ecosse done their T16 sedan

they used the slightly newer cossie 'P8' ecu with Pectel board.

Description of whats needed for cossie ecu conversion:

Ecu £50 - £350
wiring loom, ive bought an ecu 36 pin plug and made a new loom rather than cut / alter an ageing ford one! £180
PF09 TPS £40
Air & Water temp sensors £30
Crank position sensor £30
Phase sensor £20
Amal valve (boost control) £25
set of IW-044 injectors (good for 270 bhp) £80
Sierra 4x4 throttle body with idle control valve £90

Wasted spark driver £140
Loom for above £65
twin ignition amps £60
PSA coil pack and 8v leads

Have to figure out a way to fit a cossie trigger wheel to the crank pulley, cossie's used an unusual setup, 4 teeth
spaced 90 degrees apart

finally modifying gti6 vacuum pump for the phase sensor, im using the sierra's distributor trigger wheel mounted
onto the vacuum pump shaft, very very difficult but dooable

At times i wish i'd not bothered with the cossie ecu idea as there is so much to buy and so many things have to be adapted. I did briefly consider using Calibra C20 LET manaement as this alraedy has the 60-2 crank position sensing
but nobody does a wasted spark conversion for it and i'm not clever enough to think of a way round it!!

Obviously stand alone, Megasquirt, omex etc, is the way to go but iv'e already gathered £100's worth of cossie bits
and its proven to work so, right now, this seems the best way to go, for now...

Power wise, i'd be over the moon with around 250 bhp with similar helpings of torque, this will never be a track

car so for road use i think this is a decent 'goal' to aim for, obviously any more would be a bonus!

There are lots more problems to overcome such as the termostat housing, the pipes come out in the wrong place so

will come into contact with a rather hot manifold, so only way (that i can see) round it is to blank the existing fittings

off, then drill the underside of the housing and fit 2 new fittings. Its easy to see why turbo conversions cost what they

do, so much redesigning/positioning etc etc pretty much everything needs to be made from scratch.


So there you go guys, over the next few months all these bits and pieces should hopefully come together to create

something along the lines of a T16, i will put pics up as soon as i can find a way to resize images, my computing

skills are some what basic!!

ive looked at just about every piston option, the saab has a much bigger bore diameter, cant remember exact size

off top of my head.

the gti6 ecu: i'm really not convinced that it would work, as far as im aware they cant realise positive inlet pressure

yes, i know it works for superchargers but i think asking it to manage a turbo is pushing it.

i appreciate all comments/advice etc

btw, the TD04 16T is one of my potential choices

Speak to sos motorsport they are up in jock land they will be able to help you out.

________________________________________

how the feck does it work on the superchargers then??

________________________________________

need a part number? get on here - http://public.servicebox.peugeot.com

Bring on the Trumpets.

but the ecu doesnt use lambda on WOT?


why would you use a smaller cosworth throttle body BTW?

sounds like you need to use an 8v turbo ecu with a modified map sensor.

________________________________________

need a part number? get on here - http://public.servicebox.peugeot.com

Bring on the Trumpets.

if i want to go cossie management then i have to use its throttle body, because it has an integral idle valve and i cant

think of a way round it, plus it saves all the hassle of trying to custom fit the TPS to other bodies etc etc,

as for the bosch 3.2 ecu from the 8VT, according to Dastek they can remap/alter eprom so it will suit new engine,

i have played about with the map sensor on these before (my old phase 1 xsi 8VT) by adding resistors in, i could have

swore that i raised the fuel cut point a bit, but no dyno proof to back this up

xantia and 406-RGX, dished pistons XM and 605 RGY, flat top pistons, arguably same as T16

RGX/Y is a good block to use as it already has turbo oil feed and drains

my build is a budget one so no forged goodies here! i'm aiming for around 250 bhp, i think 250 in a 306 will make a

good road car. I just cant decide between machined RGX pistons/bottom end or just use the complete gti6 engine with

a decompression plate, look at what dp engineering get away with!

There's a bolt in the back covering up a feed hole, in the same place as the diesels. Just get a Diesel oil feed line chopped with a compression fitting as the fitting on the block end is wierd.

A phone call to Dave at SOS motorsport he is soundsofsilence on here, or look up SOS motorsport on Facebook, they have built loads of 16v turbo lumps dir 205's and 306's and have went down diffrent routes but well worth a call or a pm

________________________________________

In my garage just now

2003 BMW M3 & 2009 L200 Raging Bull
& Audi Q5 S Line
AX stock rod & Saxo Stock rod
Sold the bike an charged rallye an bought a caravan, midlife crisis or what!

jsa666

this is what iam gooing to do just witha decomp-plate and lynx headgasket.
find danish 6 in projects

kenneth

T5D5 - TD04-19T at a decent price that I want but cant afford grrrr...

________________________________________

Nothing to see here