306 gti6 8v turbo

[eddygti6]

just joined up to find out abit info on the 406 sri engine. what to do, what not to do and where to buy parts from.
anyway i have a 306 gti6 and i am on fitting a 406 sri engine. i bought the engine from a lad in scotland and was told basicley fit it and go. so i got the engine home, fitted it to find he had gave me the wrong wiring loom so thought well while the engine aint fitted properley take it back out to do the head gasket and service the engine. took the head off to find 5 bent valves, removed the cam pully to find the pullye key had snapped. i wasnt happy. i have finaly found a cam pully after looking for one for the past 2 weeks
planning on buying a few parts from dp-engineering.

anyway here is my progress with lots of pics

1st of all here is how my 306 is looking at the minute, there has been alot of work gone in to this car in the past few months.








saturday 22nd may i had a drive up to perth from durham to get the 8v turbo engine and spare parts.




got up there for around 9am to load the engines in





as you can see... that slammed the back end of the dirty diesel coming back down the A1 it was struggling get get to the speed limit
but we finaly made it home and took the engine out ready to fit to my 6,







started off by putting on the extended engine mount




then lifted the engine in to place and fitting the engine mounts




thats as far as i got on saturday. now i am having to remove the engine again as the thubo is louching the bulk head and while its out i am going to replace all the gaskets and belts and give it a full clean over. also i have a 205 1.9 gti cam to fit as they have a higher lift than the standard 406 cam

stripped the head on the full engine to find there were 5 bent valves. i got a spare head when i got the engine so planning on stripping it, changing the tappets and fit the 205 gti cam i have.

i modified my dash a little moved my head unit and made i template for my gauges, also stripped the head and cleaned everything ready for fitting to the new head



made myself a cardboard template of the gauges




i made a start on building the new head up and got a few pics of the damage from the old head, the belt has slipped due to the key on the cam pully snapping, decided while i had it apart to clean all i could and get the engine looking nice and tidy for when i refit it







new head all cleaned and painted ready for rebuild, fitting a 205 1.9 gti cam









next it was time to do something with the turbo & manifold






then i recieved so shiney bits





on friday i cleaned the pistons, had the head skimmed and finaly got the engine back together ready to do the timing belt and get the gear box on next week. once fcs is out the way i can get the loom sent of and sorted out then just needing wheels and a paint job.

[DiscoPol]

Hello and welcome on in mate ,

thats an impressive set of pics ,

sadly i wont be much use to you,(HDi chap and fairly limited knowledge at that)

but i do know we have a few members driving the SRi 406 and some of the other guys are an absolute font of knowledge on all things 406 so im sure we will be able to help out where we can.


Polskipug

[mjb]

While you've got some access to it, fit yourself a new ECU CTS (if memory serves the one with the brown plug is for the ECU) as they tend to expire and can cause rough idling. Getting to it later is a pain

[Welly]

Excellent work and thanks for posting

The old engine looked manky at first, how the hell did you clean up the pistons

Looking forward to more progress.......

[Bailes1992]

They look like new pistons to me:) Possibly with a bigger 'dip' to reduce compression. Although I might just be making that up and maybe he did clean them. How come you didn't just turbocharge the GTi-6 Lump? You keeping the GTI-6 gearbox?

[sirwiggum]

Stunning

Nice one, looking forward to more progress!

If I was any good at mechanicals, I would be tempted to rip the suspension out of a Xantia to let it get over big speed bumps and/or kerbs

[eddygti6]

my engine is now toghther


Thanks for the reply people a few things 1st...

1# fit yourself a new ECU CTS (if memory serves the one with the brown plug is for the ECU). where will i find this brown and where do i get a new one?
2# where do the fuel pipes fit the fuel rail? i have 3 pipes to the fuel rail but not sure where the feed and return go?

3# where do the pipes from the throttle body go?


to answer a for questions:

1# how the hell did you clean up the pistons = wire brush on a drill then a bit of wet and dry to smooth them over and a lick of WD40
2# How come you didn't just turbocharge the GTi-6 Lump? = i have had 3 GTI6 engines in this car and had nothing but hassle with them, to turbo one of these engines i would be looking ar around £3k but i only paid £120 for the sri engine and with all the added extras i have bought its starting to add up at this present moment, every thing i have spent on buying the engine and all the nice shiney bits and service parts have add up to just shy of £500 i would say that is a cheap way to turbochraging and car
3# You keeping the GTI-6 gearbox? = yes

[eddygti6]

my engine is now toghther


Thanks for the reply people a few things 1st...

1# fit yourself a new ECU CTS (if memory serves the one with the brown plug is for the ECU). where will i find this brown and where do i get a new one?
2# where do the fuel pipes fit the fuel rail? i have 3 pipes to the fuel rail but not sure where the feed and return go?

3# where do the pipes from the throttle body go?


to answer a for questions:

1# how the hell did you clean up the pistons = wire brush on a drill then a bit of wet and dry to smooth them over and a lick of WD40
2# How come you didn't just turbocharge the GTi-6 Lump? = i have had 3 GTI6 engines in this car and had nothing but hassle with them, to turbo one of these engines i would be looking ar around £3k but i only paid £120 for the sri engine and with all the added extras i have bought its starting to add up at this present moment, every thing i have spent on buying the engine and all the nice shiney bits and service parts have add up to just shy of £500 i would say that is a cheap way to turbochraging and car
3# You keeping the GTI-6 gearbox? = yes

[eddygti6]

does anyone no of anyone who has fitted a 205 1.9gti manifold? i have been told they fit but i cant see how as the 205 inlets are square and the 406 8v has pear shape inlets. i already have a 205 gti cam fitted with a bigger intercooler, fuel pressure reg and manual boost controler to adjust the boost. hoping to get this on the road next mont and getting it booked in with my whippy to get the ecu uncoded and remapped so i can up the boost past 14psi

[mjb]

1# fit yourself a new ECU CTS (if memory serves the one with the brown plug is for the ECU). where will i find this brown and where do i get a new one?

There's three CTS's to the left in this picture - brown green and blue. A quick look on servicebox shows the ECU one is the green one, part 1920 Q2

The others are:
133856 Maroon "INFO ON CENTRAL TEMP CONTROL HOUSING"
and
133848 Blue "SENSOR ENGINE" "...WITHOUT AIR CONDITIONING"
or
133834 Blue "TEMPERATURE" "INFO WATER TEMPERATURE FOR DISPLAY"

[trem1]

hi there eddygti6 unless im very much mistaken,the pic with the 106 and landrover is taken in stanley,co durham isnt it??

nice car btw i'll keep my eyes open for a low-flying pug while im in that area,if im right of course

[eddygti6]

hi there eddygti6 unless im very much mistaken,the pic with the 106 and landrover is taken in stanley,co durham isnt it??

nice car btw i'll keep my eyes open for a low-flying pug while im in that area,if im right of course

yes mate it is stanley indeed the 106 is my girlfriends car, only that los as it had 2 engines in the back i am not driving anything at the minute. today i got the timingbelt on and was putting the aux belt on when i snapped a bolt in the tentioner so now i have changed the aux set up to a 306 rallye aux set up. i am away this weekend down at the french car show at rockingham so nothing will be getting done this weekend, all depending on work next week if i get time i am hoping to have the engine and box in and the loom sent away to get rewired

[TooT]

I love reading stuff like this. Sometimes i wish i had the skill, confidence, knowledge, patients, tools, space, time to do something like this.

Good work

[eddygti6]

I love reading stuff like this. Sometimes i wish i had the skill, confidence, knowledge, patients, tools, space, time to do something like this.

Good work

room, patients? what is that? haha i aint got any of that

[tenwierdufos]

Cant see if this has been answerd but i will have a go anyway haha

The 3 pipes on the fuel rail...

There will be 1 on the rail (main one from the fuel pump)

and 2 on the regulator (circular part you can see on your own pics)

one of the pipes on that possibly underneath) will be for the fuel return, the other will be a vacuum pipe to go to the inlet manifold to ajust pressure for load ;)

hope thats some use.