309 gti6 turbo project

[bobdylan55]

hi people, fairly new to this forum but a few of you might know me from other forums such as 106 rallye, 309 owners, 306gti6 etc.

i thought id introduce myself properly and show you all my project.
copied from other project thread on 106 rallye so sorry if bits dont work (or makesense)

Before





After cleaning









sorry for poor after pics, i managed to move it under the tree into the corner of the drive and then realise i hadnt taken pics and had to rush off to work will try get some better ones when i next get it out.

Next things to do will be taking the bumpers off for repair, and freshening up. spoiler will be taken off as its hanging off, and then might fit a ph2 spoiler.
Front bumper will probably be staying off, and front end removing so the engine can be slid out.

started the day just planning on taking the bumpers off to repair them. just after removing the front bumper, rajj decides to persuade me to rag the engine out lol
so here are todays pictures in order






























am working tomorow so cant get the engine apart, but should be done soon

[bobdylan55]

another update

s16 pistons and crank have arrived.

fitted new crank bearings and crank as below

new shells



new crank



Seems a little stiff to turn tho, and havent even tightened it up fully yet, its about 30nm instead of the 50 its surposed to be :S hopefully its just because its running on cam lube and not oil.


decompression plate has arrived Ferriday engineering really are top notch. I finalised the headgasket dimensions on sunday night, it arrived tuesday morning :O i dont know how lol, but its perfect and im really happy







Also brought another turbo just to be on the safe side when designing my manifold, as they both have different outlet port angles

This ones a spanking new t34 t4 t04e whatever that means lol, but it is pretty much the same as the other one 400bhp 40psi compatible, and also has a different angle on the outlet.




more goodies arrived today

left to right
lower gasket kit, cambelt kit, water pump, piston rings, head bolts



will hopefully get some time later or tomorow morning to order my headgasket, oil filter, and a gti6 crank sprocket (apparently slightly different from the one i have :s


right been and brought an oil filter, nothing special so no pic

Also just stripped the megasquirt out of the 106






more updates

engine is finally taking some form of usefulness.

firstly i decided to take crank out again, and change both end seals. Also needed to re silicone the side plates back on.
i then put the new pistons rings onto the s16 pistons, and then put the pistons into the j2te block







oil pump was put back in, along with all the chain and crank gears etc. Noticed that it didnt have an oil pump spacer plate :S which i thought was unusual...
cleaned up the sump a bit, scotchbrite and some gunk.
also cleaned the block a bit, and gave it a quick once over with some black high temp paint, and then polished the sides back to metal.

[bobdylan55]

big update

got the decompression plate and head on, all timed up, and into car














tacked up, and it goes something like this








well here it is, the manifold complete

[bobdylan55]

well got fedup of waiting for cash income lol so found some paint i had in garage sanded down my inlet and painted it.

so, from this ugly thing


sanded


to this




plans are to do the rockers the same colour blue, and then paint all bolts holding the covers down white. then blue hosing obviously to suit, blue silicon adapters for the inlet piping etc.

intercooler bracket made and fitted, pipe work also fitted, however ran out with one pipe left needed only 20cm aswell lol.

[bobdylan55]

its probably going to be easier to post the entire thread as a link if thats ok?

http://www.309ownersclub.com/Community/ ... =30&t=3403

[FarmerPug]

Wow that looks much better now, i only ever had a diesel 309 but that thing looks quick, did the 309 even get a turbo as standard and what sort of power are you getting out of it. As for the honest john review which doesnt like the styling of the 309, i cant understand why it looks fantastic its a lower and longer 205 which is great. Watch you dont rip them seats in the back storing parts there that interior would look good with a clean.

[bobdylan55]

im not bothered about the seats, theyre getting chucked and replaced wuith buckets. didnt come with a turbo as standard no, this is a gti6 engine from 306 with a turbo. should be about 300-350 when its finished.

[steve_earwig]

Interesting amount of fabrication going on there I've never seen a compression plate before, seems an easier alternative to machining pistons. How is it sealed to the block? Pedal box reminds me of something I once drove, bit weird at first... VW Beetle

Btw all the ratios are there on Service Box, just pull up the parts diagrams for the gearbox, it even tells you how many teeth everything has.

[bobdylan55]

the decomp plate is pretty wierd. It uses a standard head gasket between itself and the block, and then a non setting sealant between itself and the head, however the sealant is only applied around the water and oil ways, and not the pistons. Apparently the head bolts compress the head to the block and the fire rings on the headgasket do not compress as much and force into the decomp plate making it deform into the head. if that makes sense? lol

[steve_earwig]

Ah yes, I can see you applying the green goop there. It does make sense, kind of

[FarmerPug]

350 bhp in a front wheel drive car, is that not going to be a bit understeerey.
But the 309 is a fine car i had a pair of glds which were some way behind even 100bhp. But the old diesel engine was tough the red one when i bought it was mint it started on the button and sounded like new even with 214k miles. there wasnt a dent, or spot of rust anywhere, the white one looked good but the place where the front shocks sat were severly rusted and thats what ended it but after a year or so getting rallied round the farm they did look their age:
The £70 one

The £90 one


Now they dont compare to that great work your doing, but even these pair of old diesels were an absolute ball to drive especially with a good handbrake on a mildy wet field.

[steve_earwig]

What happened in that last pic, did you pi$$ off a bull?

[FarmerPug]

There is a number of different things in that side of the car, some were turning too soon and hitting posts, but mainly handbrake turns that caused the car to touch other objects with some force, the whole was a tractor which reversed into it with a buckrake on, the other side continued the theme, i even put a mirror on and it got broke:

[bobdylan55]

yes might be a bit understeery, but the car was originally designed for HKS fwd drag racing as a uni project. For track ill probably have a seperate map on megasquirt and limit the boost to 10 psi and run about 250bhp.

[FarmerPug]

given the fact you have done all this, i think you should be good at answering this question, or any other members with enough knoledge;
i have a suzuki samurai it had the 1.3, i pulled it out and am replacing it with the 1.68v of the vitara, when i put the vitaras engine in can i add on a 16v head, im not great at mecanicing and the only reason i got the engine and gearbox out is its so easy in a samurai. But apart from undoing bolts and pipes what elese is involved in swapping heads. They are all carbed engines, will that need improved?
Im already a member of the suzuki forum but its a ghost town.