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 Posted: Fri Jan 31, 2014 3:08 pm |
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Joined: Jun 14, 2011
Posts: 16
Trade Rating: 0
Location: Sofia/Bulgaria
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Hi everyone,
as I'm heading towards finishing my build I thought I'd share it with the community here.
The car is a 1999 206 GTI 138 sans multiplex. I have owned the car since 2010 and until last year the car was 100% stock. At first the idea was only to swap the inlet and exhaust manifolds from the GTI180, however I decided to go a bit further.
Please, take into account this is a daily, street driven car occasionally used at track days, so the extent of the build only goes so far (for now). In time, hopefully the car will develop further.
At the last TA session last season (only modifications at the time: KW V1, CompBrake CNC fixed spherical bearing top mounts and EXTREME stainless steel exhaust system):
Current setup:
EW10J4 Engine
Stage 2+ head
Blueprinted, Ported & Polished GTI180 Inlet manifold
Blueprinted, Ported & Polished 2.75 inch Dell’Orto TB
Blocked EGR
GTI180 Exhaust manifold
EXTREME Custom 2.5 inch Stainless steel exhaust system
GTI180 Exhaust heat shield
GTI180 Injectors
RACE_FACE Custom Fuel rail
AEM FPR
Marshall Shock Proof FP gauge
GTI180 Alternator
GTI180 Gearbox mechanism (cables, etc)
DENSO Iridium power
KW V1
CompBrake CNC fixed spherical bearing top mounts
Last year I baselined the car 100% stock before any interventions took place and the result was 116WHP and 157WNM. This was recorded on a Mustang MD-AWD-500-SE dyno.
What we've noticed is that out of the factory the car comes leaned out a bit (still very safe though). I'm currently running stock cams and ECU at this stage. Baseline to tune plot comparison should be interesting when the car is done.
Difference between Dell'Orto TB and the OEM unit
RACE_FACE Fuel rail with GTI180 injectors fitted
Oil dipstick powder coated
AEM FPR
Marshall shock proof FP gauge
CompBrake CNC fixed spherical bearing top mounts
GTI180 Exhaust manifold (sandblasted)
Head is assembled with the valves in place
There is still some work left and I'm still waiting on a couple of parts, but hopefully the car will be finished by the end of next week. I will post the results after the modifications as soon as we start the car and map it. I believe this pretty much covers all mods to the best of my memory. If I remember anything I've missed I'll be sure to add it on here. If you have any questions, please don't hesitate to ask.
Stay tuned for more info and pics 
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| GTI UN JOUR.. GTI TOUJOURS. | |
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Last edited by lrc_toto on Fri Jan 31, 2014 3:34 pm; edited 1 time in total
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Posted: Fri Jan 31, 2014 3:28 pm |
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Joined: Feb 08, 2010
Posts: 7045
Trade Rating: +5
Location: In the garage
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Looks good. Refreshing to see a standard looking 206 on the outside.
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| 2001 GTi 138, Bilstein Sprint dampers, H&R springs, 21mm Peugeot Sport torsion bars, 22mm rear ARB, Peugeot Sport Group A wishbones, 283mm discs, Goodridge stainless hoses, Maniflow 304 grade 4-2-1 2.5" manifold and system, 200 cell cat, Richard Longman head, 45mm Jenvey throttle bodies, 9.5mm TB spacers, 90mm air horns, Jenvey throttle linkage, Jenvey fuel rail, Aeromotive and Goodridge fuel fittings and braided hose, ITG sausage filter, Radtec custom radiator, Piper Ultimate Road cams, Piper vernier pulleys, Omex 600 ECU. Saxo electric PAS pump, Vibra Technics engine mounts. Samco coolant hoses, TTV steel flywheel, 4.76 final drive ratio, 307 CC 180 ratios. 2019 BMW 530i. 2017 Mercedes C300 convertible. | |
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Posted: Sat Feb 01, 2014 11:13 am |
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Joined: Feb 10, 2010
Posts: 4266
Trade Rating: +4
Location: Palestine
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Well done my friend,I like the mechanical tuning 
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Posted: Sat Feb 01, 2014 1:46 pm |
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Joined: Jun 04, 2010
Posts: 1691
Trade Rating: +3
Location: northallerton
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nice to see another 206 being modded for speed, is that rr printout without a re-map
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Posted: Sun Feb 02, 2014 12:56 am |
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Joined: Jun 14, 2011
Posts: 16
Trade Rating: 0
Location: Sofia/Bulgaria
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Cheers lads,
@usher yes, completely stock. The graph hasn't been touched.
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| GTI UN JOUR.. GTI TOUJOURS. | |
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Posted: Sun Feb 02, 2014 2:03 am |
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Joined: Jun 04, 2010
Posts: 1691
Trade Rating: +3
Location: northallerton
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That explains it had a look on mine with cam's and a remap I got 120whp so after the map you should get a good gain. I'm looking at the 180 inlet but can't find accurate results on gains for that alone. Itbs are still a possibility
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Posted: Sun Feb 02, 2014 11:33 pm |
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Joined: Jun 14, 2011
Posts: 16
Trade Rating: 0
Location: Sofia/Bulgaria
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That's strange!?! Only 4WHP difference and you had cams and a remap? Did you baseline it before the cams and remap? What were your mods at the time? What dyno was it?
Keep in mind this car was absolutely stock when measured at the dyno (stock exhaust, cat, stock intake, regular petrol, etc).
The GTI180 inlet manifold alone won't make much of a difference. Needless to say, head work is needed for bigger gains as the stock one presents some noticeable restrictions.
For real gains with ITBs you will need a stand-alone ECU.
EXTREME Custom 2.5inch stainless steel exhaust system
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| GTI UN JOUR.. GTI TOUJOURS. | |
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Last edited by lrc_toto on Mon Feb 03, 2014 2:01 am; edited 1 time in total
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Posted: Sun Feb 02, 2014 11:46 pm |
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Joined: Jun 04, 2010
Posts: 1691
Trade Rating: +3
Location: northallerton
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the cams i have are a re-profile so nothing extreme, i had exhaust manifold, induction kit and port and polished throttle body at the time and gained 12 bhp on the re map engine power
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Posted: Tue May 20, 2014 7:50 am |
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Joined: Jun 14, 2011
Posts: 16
Trade Rating: 0
Location: Sofia/Bulgaria
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| GTI UN JOUR.. GTI TOUJOURS. | |
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Posted: Wed May 21, 2014 6:56 am |
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Joined: Jun 14, 2011
Posts: 16
Trade Rating: 0
Location: Sofia/Bulgaria
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| GTI UN JOUR.. GTI TOUJOURS. | |
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Posted: Wed May 21, 2014 7:27 am |
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Joined: Mar 22, 2012
Posts: 235
Trade Rating: 0
Location: ireland
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great job i like those engine mods!!what was the cost of them?
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2000 gti 138,tein superstreet coilovers front,tein adjustable shocks rear,22mm rear arb,carbon fibre strut brace, 6 point omp cage,fibre glass bonnet,polycarb windows,406 v6 brembo 4 pots,carbon Lorraine rc6 pads,brembo 307hdi front discs,406 v6 master cylinder,braided hoses all round,306 gti-6 brake reservoir,abs removed,4.9 cwp with 3j driveline plated lsd,compbrake quickshift,k&n filter with cold air feed pipe,4 branch mani,decat,sportex straight thru race system,mocal oil cooler,group n engine mounts,omp bucket seats,omp steering wheel,battery relocated to boot,4 point harnesses,15'team dynamics pro race 1.2 on Michelin slicks | |
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Posted: Sat May 24, 2014 10:29 am |
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Joined: Feb 07, 2010
Posts: 620
Trade Rating: 0
Location: Malaysia
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nice!
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Posted: Sun Jun 15, 2014 1:10 pm |
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Joined: Jun 14, 2011
Posts: 16
Trade Rating: 0
Location: Sofia/Bulgaria
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@jonsully, I don't want to say what the cost of the engine mods was as I think many people here spending big £ on their cars won't be happy and will get demotivated 
just to put things into perspective the following:
Stage 2+ head
Blueprinted, Ported & Polished GTI180 Inlet manifold
Blueprinted, Ported & Polished 2.75 inch Dell’Orto TB
Blocked EGR
GTI180 Exhaust heat shield
GTI180 Injectors
cost me less than £200
If there ever was a contest BHP gained per £ spent I will win quite easily 
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| GTI UN JOUR.. GTI TOUJOURS. | |
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Posted: Sun Jun 15, 2014 1:30 pm |
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Joined: Jan 05, 2013
Posts: 114
Trade Rating: 0
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Are the Compbrake top mounts easy to fit ?
There seem to be some problems on the 106 and 306 model, but from what I've seen they are just fine on a 206. Thinking about getting them too. Did you modify them to fit the KWs ?
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Posted: Sun Jun 15, 2014 5:20 pm |
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Joined: Jun 14, 2011
Posts: 16
Trade Rating: 0
Location: Sofia/Bulgaria
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The CompBrake top mounts for the 206 are a direct fit and quite easy to install. One of the few things that really are "plug&play" for the 206 in my experience.  I'm very happy with them.
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| GTI UN JOUR.. GTI TOUJOURS. | |
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