Engine Conversion at the Weekend

Johnathan · **Postat:** 2006-05-04, 22:29

Traveling 140 miles at the weekend to do an engine conversion in 1 and a half days!

The conversion is an engine replacement/upgrade, wiring, control unit, rear axle (with discs on), and rear braking set up. It should be fun, and i will post pics up of the speedy transformation when i get back.

Anthon · **Postat:** 2006-05-04, 23:53

what car?

my nova engine swap took a few hours only, just nightmare tracking down the different coil i needed!

Johnathan · **Postat:** 2006-05-05, 00:10

Its a 106 i think, really quite a good lttle project.

The engine swap i anticipate will only take a few hours too, but we will see what condition its in first. Its a conversion to plant a VTS lump into it, along with anything else it might need, which should be fun! Everything should be a straight swap though, like the wiring and ECU. Axle again is not a hard job, but the time consuming part will be making brake pipes, and other such creative tasks ;)

Its just like the CVH, i can have those out in 40 minutes!

Anthon · **Postat:** 2006-05-05, 09:48

ahhh the rear disc vts conversion then

106 should be ok, most of them are not old enough to be wrecks by now

should of spoken to mankee - remember he has a VTS'd 106 rallye!

well its the 106 GTi engine, but its the same lump!

Johnathan · **Postat:** 2006-05-05, 13:59

yeah thats it, i forgot about him though to be honest.

The engine will go straight in, and mate up to everything else as per citroen/peugeot usually do anyways. Your right, hopefully it will be in good enough condition to dismantle easily! Once thats in and everything except the wiring is plugged in/up, its time for the rear axle off, and new one on again, with fresh brake pipes bled up and working splendid.

after thats done, and its on its arse/wheels again, its time to melt all the wires ;), cough i mean wire the ecu, loom, and imobiliser in.

Do you know of any problems mating up the VTS wiring loom with the 106?

Johnathan · **Postat:** 2006-05-11, 17:23

Well this was a fun trip at the weekend!!

As far as we knew this conversion was going to be fairly easy, and in principle it is, when you have all the right stuff from the start. We turned up at where we were doing the conversion (which is 150 miles from where i live), and we were expecting all the parts to be delivered on time, as the job was to last two days. I ended up being there four!

Unfortunatly, on the first day, the parts did not even arrive until 4:00pm which meant that once the engine had been taken out we had about 4 hours to spare, which were wasted. Thats only the start of the problems though. The place that was delivering the parts, had missed off most of the bits we needed, like exhaust downpipe, oil filler cap (?? i mean eh ??), and other vital bits .. the bites they did deliver were either bent or broken (like the axle & metal water pipes)

The job as far as we knew it was to fit a rear axle (easy), fit a different engine (easy), and engine loom along with ecu and other little obvious bits (easy). Unforunatly the conversion actually requires all the wiring from inside the donor car too, because the ecu runs from a coded key/transponder system, and will not run without it .. So the job which should have taken two days, actually took nearly four, and is not finished yet .. i am going back this weekend.

I have a few pictures below, and some of them are poor quality due to my flash not working right, and it was dark most of the time, due to waiting for parts, and working from 8 in the morning till midnight nearly every night .. if only the engine and parts supplier had not been a tool!!

Car - Peugeot 106 XSi

Engine out - 106 XSi 1.4
Engine in - Saxo VTS 1.6 16v
Engine loom from a peugeot 106 GTi
Whole loom from a peugeot 106 GTi
Axle from Saxo VTS (rear disc conversion) Twice because the first one is bent!!

Other parts to fit were ..

New handbrake cales
New rear calipers
Brakes all round
New brake pipes (obviously made by us)
Engine oil & filter
Gear oil
VTS downpipe
Dash board out (for wiring inside)
New fuel pump and sender wiring needs to be made)

anyway, pictures..

The Car

Just been painted

The old engine

Engine Out

New axle arrives and appears bent!!

Engine loom and ecu

VTS engine ready to go back in, but the engine mount needs adjusting

Water pipe on engine bent

Time to modify the origing mounting so that the engine will fit in the engine bay .. angle grinders at the ready

Old VTS Mounting which is wrong

Engine the slots in perfectly (at last something is going right)

Difference in downpipes

Okay then, time to fit the axle .. old one off.

New one on ..

disc conversion done, and new calipers bled up with new pipes.

Does anyone see anything wrong with this wheel?? Time for the second axle !!

then its time to tackle the rest of the wiring in the car which we did not know we needed to do, until the second day being there .. hence, we wernt very happy!

Still at it, at midnight!

So i will back at it this weekend aswell, and the next set of pics should show it driving away!! The job should hev been easy, but the garage that supplied the parts, and advised the lad whos car it is, has complicated things no end, by not being honest, and supplying dodgy bits..

anyway, to be continued ..

Don Kamiel · **Postat:** 2006-05-11, 18:31

Well done !

Anthon · **Postat:** 2006-05-11, 22:46

christ mate! no wonder you were annoyed!

Johnathan · **Postat:** 2006-05-11, 22:51

yeah thats it, bloody thing it is.

mind you like i said, its the fault of the guy who supplied the parts being slacker then something really really slack! Need to finish it, as i have another engine to build next week. :)

Tidgy · **Postat:** 2006-05-12, 13:24

never put one on but had some fun taking one out with a mate, wiring loom is a pain on them to get at.

Johnathan · **Postat:** 2006-05-12, 13:35

yeah they go under the wheel arch on what seems like an endless row of clips.

once its out its not that big though, making it a bit easier.

the new loom is in now, and turning on the key before i came back home, so its just a case of getting it to fire now, and then the poor lad whos car it is can have it back.

Tidgy · **Postat:** 2006-05-12, 13:44

lol, bet he can't wait

Johnathan · **Postat:** 2006-05-12, 14:19

yeah well its a 30bhp hike in power (which aint to be sniffed at, lol), and he will be stopping a lot better with his new brakes too. Not just that but he has been without a motor for a week on monday.

Tidgy · **Postat:** 2006-05-12, 14:53

lmao, he'll be going mad, god knows how i managed without the scoob for 8 months

Johnathan · **Postat:** 2006-05-15, 21:26

Well more fun and games happened this weekend. We thought we would get the car going, and were very confident. We managed to get everything in and finished.

Alas, we hit more problems then. We had engine problems relating to the ecu. And the alarm was not working correctly. It was refusing to immobilise, and the Ecu appears to be faulty.

SO, after two whole weekends, and many hours on this car, the lad who owns it finally got fed up with the the parts which had been supplied from his source, and decided to take them back. This means that we had to remove everything we had done, back to a bare shell again!. Engine back out, and full engine and interior loom back out again, ready to be returned.

He is now getting another donor car, for us to do the conversion from a car which we know is running ..

Looks like i will be up again next weekend!