No worries, glad the ECU is OK

________________________________________

Contact Details:

rich@lynxpowerengineering.co.uk
07732 822546

Good luck...

________________________________________

Team Supercharged Gti-6

NV Motorsport
Automotive Performance Tuning
0121 448 7515
ECU Remapping/ DPF removal
VAG/BMW Diag and Option Coding
Peugeot Planet ECU coding/transponder programming etc
www.nvmotorsport.com
Facebook Page
Project S6

Monster Post Warning!!!

What an eventfull fortnight I have had getting the bloody thing running!

The entire build was based on going to a Spa trackday I had booked back in January for May 12th, there seemed plenty of ‘float’ in the build programme at the time, about right then that I ended up finishing the car hours before setting of for Dover!

So, the weekend starting May 3rd, I had planned to have the car running this weekend, this would give me the week to run around in it to make sure everything was Ok.

My brother, Matt came up to help with the wiring. Some of the sensors needed extending as the throttle body had moved about 100mm towards the supercharger.



We wired up the second fuel pump via a relay, the trigger for this was the live feed from the in tank pump, that way the two pumps would run in sync. I had thought about running the second pump of a switch in the cabin, but was advised not to by the helpful people at Simtek UK, as if there was an accident the pump could not be easily shut down.

I completed the coolant pipe work, as you can see there isn’t much clearance between the charger drivebelt and the bottom hose!







Over the past few weekends I had noticed that I was missing the top coolant pipe, but I had convinced myself I must have put it in the shed or in the loft. So after turning the place upside down I still couldn’t find it, I was pretty stressed at this point as I couldn’t run the without it. I made a call to the guy that had changed the cambelt for me, after half an hour he called back to say he had found it, problem was he was near Southampton! I was determined to get the car running so me and the wife jumped into the beemer to go and get it, the perfect car for this sort of thing. 8 hours later we were back home with the pipe, here it is, only cost about £100 in fuel!



So on Sunday night we were ready to start it up for the first time, I filled the car with fluids, checked all of the fittings and all was ready. I turned it over a couple of times but it wouldn’t fire up (the reason for this will found later). We looked under the car to see my new expensive Silkolene oil pouring onto the drive, on close inspection the oil sandwich plate was fitted the wrong way round! I had put the threaded nut on backwards:



The nut you can see should be furthest from the block, resulting in the sandwich plate sitting some 10mm clear.

As a result I had to take the whole front end off, intercooler, boost pipes, radiator etc:



This is how it should be fitted:



So again, Monday morning I tried to get the thing started, but it still wouldn’t start. I wasted Monday and Tuesday fiddling around with everything trying to get it to go.

On Wednesday I returned to work, I was browsing a forum and some people had suggested I had the fuel rail plumbed in backwards, and Dr Sarty on the 205 drivers forum said it should be 10mm feed 8mm return, the opposite of what I had done, having read it on the 306 forum! I felt sick and embarrassed having wasted everybodys time, I knew what was wrong straight away.

I took Thursday and Friday off.

Thursday morning I swapped the pipes over and she fired up first time! This was it, I was going to make it!

I spent the rest of the day tidying up and fiddling with things;

Wiring tidied




I made a metal guard to protect the oil cooler from road debris that could flick up:










With the car now running I also noticed that the silicone hoses I had were collapsing under vacuum, I had some spare alloy tubing which I used as a replacement:





The 76mm to 51mm Silicone reducer was also being sucked into the manifold, as a quick fix I held the pipework back with some able ties:



So here we are finally ready to go:





This was on Thursday night, I was booked into DES at 12 on Friday for the new exhaust to be fitted.

On Friday morning I was up at 6 loading up the car and fitting the bumper and bonnet back on, fitted the 25mm arb. I started the car at 8.30 to check it and it was only running on 2 cylinders!

Again, I did my now well practiced fault finding sequence, ie plugs, injectors, pumps, power. But all was in order. I checked the ECU and the multi pin plug that goes into the top was wet. In my wisdom I have moved the ECU into the footwell to keep it safe form engine heat and to create room for the Swirl pot. What I hadn’t counted on was coolant running down the cables and into the ECU.

I took the ECU apart to find a couple of teaspoons of coolant in there, see bottom right:



So with some cotton buds, WD40, the wifes hairdryer and some very small screw drivers I cleaned up the circuits which now had some crystals forming on them. I plugged the ECU back in and all was well again, but I had missed my time slot at DES.


I took the car to my local garage who Mig welded the hole in the exhaust.




So I finally set off for Slough at 7pm on Friday, where I was stopping over night before Dover and ultimately the ‘ring and Spa.

________________________________________

205 GTI6 S

The weekend was a bit of a disaster, too much too soon to be honest.

We got there ok, I somehow lost my oil filler cap on the Friday night so we had to stop off at a pug garage in Folkstone before catching the ferry to get a replacement.

The weekend was very busy, we had to queue for 2 hours just to get on the track! I managed half a lap and this happened:



The oil cooler feed pipe burst going into Breidsheid bridge (Adenau bridge). Luckily I could get straight of the track. It was a very unpleasant experience though, there was a swarm of people looking all over my car which was now covered in oil. What was worse I had to sit and wait to see if anybody had an accident on 'my' oil knowing I would be accountable for the consequences!

Luckily nothing happened and I got away with a 20E fine.

After that I didn't go on track again and didn't go to Spa, I decided to quit whilst I was ahead and head home.

________________________________________

205 GTI6 S

harsh luck

But you still have a big for pulling out all the stops, getting it running and trekking straight over there - and if it's any consolation, as you know if it could have happened anywhere while on the lap right by Breidscheid has got to be the "least bad" place..

Focusing on the positives: what was it like for the half a lap up til that point? I'd imagine!

________________________________________

Democracy is two wolves and a lamb voting on what to have for lunch..
..Liberty is a well-armed lamb contesting the vote.

Project é - my 306 project thread.

I am not bitter about it, I did the 'running in' in one swoop. And as you say it was the best place for it to happen!

It was absoultely flying before it went though! The most noticeable benefit with so much power on tap is the grip generated, just turn in and it just drags you round, with little if any understeer.

________________________________________

205 GTI6 S

Not of half a lap, no.

________________________________________

205 GTI6 S

Gutted for you mate, at least you never had an accident or killed the engine.

Carl

________________________________________

C.G.Cars of Leicester, Peugeot/Citroen/Renault specialist Tel: 01162 624498/07799 405184 WWW.CGCARSLEICESTER.CO.UK
36 narborough road south, Leicester LE3 2fn

MOT station now open, tests £35 with a free retest.
Recovery available with a recovery unit, for those not so local jobs

Also offer the loan of a free courtesy car 306 dturbo

No answers yet.

Compression test on Friday morning before going to DES to get the new exhaust.

I will go back to the supplier with the hose and show them, see what they say.

I have bought 2 new oil filler caps, one will be a permanent spare attached to the key ring!
I don't want to go through that again!

I fixed the speedo at the weekend and fitted some bonnet pins.

There is a bit of a squeak coming from the charger belt and a bit of belt dust too, maybe I have it too tight? I will try slackening off one of the top pullies to see if it helps.

It spins up in second and struggles a bit in third too. You really have to hang on as the diff fights for grip! Speedo flies round though!

Next outing is Croft on the 21st June and then back to the ring and Spa in July.

I am also looking into some modified 406 drive shafts (probably similar to the 306) as they are much thicker than the 205/309 ones.

________________________________________

205 GTI6 S

Sorry to hear about your bad luck garry. I'll be looking forward to seeing your 205 over here in july though.

I know what you mean about the Q's onto the track at weekends. For anyone who's got a weekend planned for the summer, i'll give you a heads up that it is busier this year than ever before. Nurburgring gmbh are now running a 3rd ticket barrier for cars out on the track, on the other side of the fence to the existing barriers, in order to cope with the amount of vehicles at the weekends. Most of you will know that the barriers act as a natural 'choking' point to limit the amount of cars on the track. Obviously with the extra barrier there is a greater amout of cars on the track basically resulting in more overtaking, or being overtaken, more accidents and generally a bit less fun.

Take heed, and to anyone who is planning a trip but not yet booked, i would honestly say you would get more laps done on either a monday or friday half session, combined with a nice quite evening session on the tuesday or thursday, than you would get over a weekend with the current volume of weekend visitors.

Steve

________________________________________

Steve

Planning a ring trip? Why not stay at Hotel Burgstube

I am not so sure Dave, as far as I see it the rules are quite simple, cause and effect. I dropped the oil, they crashed, end of!
They wouldn't actually flag it either as they said it was too dangerous!

There was a brit jag later on in the day that dropped oil, 4 cars and 4 bikes come off. The driver was arrested!

You REALLY need to think about these things, its big boys rules out there. Something we are not conditioned to here in the UK.

________________________________________

205 GTI6 S

I would have actually told the marshalls to f-off, and gone running back up the track waving a red and yellow flag anyway. Imagine standing watching as a biker slides into adenau bridge on your oil spill.

________________________________________

Steve

Planning a ring trip? Why not stay at Hotel Burgstube

Thanks arctic, ecu has been remapped. It has to be to run the 440 cc injectors.

________________________________________

205 GTI6 S