#1: 206 GTI with Highly Tuned Engine - 13.07.2011 Video Added Author: Schumi, Location: Istanbul / TurkeyPosted: Thu Feb 24, 2011 5:04 pm ---- Hello Everyone.
I'm warning you. My English isnt perfect. And this is long story.
This is my buddy's 2001 206 GTI. It's our biggest project. We did try a lot of thing on this car.
Everything started after an accident. When my mate on compulsory military service, his brother crashed a truck with my mates Citroen Saxo VTS.
Dont worry he is fine and he did getout in car with out any damage even any scratch.
Anyway after he come back normal life he look a new sport car. With my suggestion he decide to buy a 2001 206 GTI. But he disapointed after owned a Saxo VTS. Stock 206 GTI is slower than VTS. So we decide make some engine tune. We started with induction mods. But not a simple air filter or cold air intake. First all of we need referance point. Go to dyno.
Dyno figures of stock engine with crappy exhaust system (come frome preview owner)
Engine Power: 138.9hp
Wheell Power: 111.2hp
Dissipate Power: 29.4hp
Max Couple: 165.1nm 4637 g/m (128.0 km/h)
Stock EW10J4 engines inlet manifold desing is really crap like Vauxhall cars. As you know that Mantzel Powerbox is very good improve on Vauxhall. Like RBC or RRC intake is also good on Honda K20 engine and Shunk intake on Honda B16 engine. Anyway we cant find any cheap brand new alternative for 206 GTI. We decide the research on OEM solutions. I'm a owner of 206 RC/GTI180. We did try find a GTI180 inlet for 206GTI but it really hard to find so close to imposiblle. Only 80 GTI180 imported to Turkey. And lower than this GTI180 engined 307 CC and C4 VTS. In Turkey car price is really high. After a big crash insurance company selling crashed cars to traders. Traders make a choice for every car. Split and send to scrapy yard for used part markets. Or repair and sell. At the moment 206 RC/GTI180 price in second hand between 10.000 euro and 13.000 euro. So crashed GTI180 nearly never splitted. Thats is also same on EW12 2.2 engine. Only few 406 Coupe and 607 using this engine in our country. I dont think total EW12 engined cars amount is higher than 20. But after long scrap yard research we did find EW12 intake manifold. Seller didnt know this parts origin He is thinking this part from Toyota or Mazda. Last edited by Schumi on Wed Jul 13, 2011 2:53 pm; edited 1 time in total
#2: Re: 206 GTI with Highly Tuned engine (Pistons, Cams, Head, e Author: Schumi, Location: Istanbul / TurkeyPosted: Thu Feb 24, 2011 5:05 pm ---- And project thread useless without picture. So pictures is starting.
Stage One
The EW12J4 intake manifold is cleaning for installation.
Last picture of stock engine bay.
Removed intake pipes and throttle body.
Removed intake manifold.
Installed new manifold.
Custom flange/spacer for use stock throttle body with new manifold.
Almost done.
And finish.
Last edited by Schumi on Thu Feb 24, 2011 5:09 pm; edited 1 time in total
#3: Re: 206 GTI with Highly Tuned engine (Pistons, Cams, Head, e Author: Schumi, Location: Istanbul / TurkeyPosted: Thu Feb 24, 2011 5:05 pm ---- Firts impression is just WOOUUVV. It is like a magic touch with magical stick. Huge differenc on high revs. Engine AFR is not goot at low revs. We defenatly need remap for AFR correction and rise the redline. Because it isnt hard the understand car need more revs. We did go local tuner for remap. Its also owner of same dyno of we did run when engine stock. Result is really good. 10 hp improve on peak power. But our tuners ecu reading device didnt want to read our ECU. We have to remove ECU and open inside. Desolder eprom and read on computer attached eprom device. Download ECU software. Change values. Write eprom againg. Solder on ECU. Connect car. Make a new dyno. Review new power curve and AFR. Bla bla bla. It is like torture. And we have to make this after every mod on engine. Like performance camshafts. So we suspend this remap operation. After one mounth we did see a item on our local ebay alternative. Kentcams PT60 camshafts for 206GTI. It is also cheap. And another suprise. Seller of cams is previous owner of our 206 GTI. They are also working on a tuneshop (actualy shop for twin halo lights, led taillights etc. not any performance products and works). After a deal we bought that one. But he warned we. After puting cams the car will slow down. And they didnt find why and remove after one month. And there opinion 206 GTI never can be fast car. We smile him and left there. Sorry guys but i cant find pictures of camshafts.
We did go to garage with our new toys (cams) and after installation we did run on dyno. But what is that. Just 3 hp improve on peak hp. That must juke. We did go back our garage and check every thing. Cam timing etc. But everything ok. Our stock camshaft pulleys is solid one. We did go againg scrap yard to find 1999 year 206 GTI camshaft pulleys. That pulleys is adjustable one. After pulley change at our garage we took car to our local tuner. They have Kentcams Timing Adjusting Discs like in picture. After tunershop owners do a perfect timing now its time to go dyno againg. And its works. We get totaly 8 hp in peak power with cams and timings. Our new power figure is 157 hp.
KentCams Timing Disc
Adjustable Pulleys
After few mounth later we decide do remap again. Because after intake manifold low end is realy dead and AFR is incorrect. In town driving is sucks and fuel consumption is really high in town. But fine in highways. Like i say before. ECU remap on that car (for a perfect job) is real torture. AFR corrected, town driving fixed, fuel consumption is lowered. But what about our new power figure. 5 hp more on peak power. If we have to honest we are waiting 10 hp with remap. Local tuners said that is limit of soft remap. Is it possible get a little more power on software. But he hear knock and engine stop light up after knock detection. Gas quality of country didnt allow higher advance on ignition.
That is our final of stage 1 and starting of stage two
#4: Re: 206 GTI with Highly Tuned engine (Pistons, Cams, Head, e Author: Schumi, Location: Istanbul / TurkeyPosted: Thu Feb 24, 2011 5:05 pm ---- Stage Two
In summer our a friend from Peugeot Club Turkey come back Turkey for holiday from Belgium with his 206 GTI. After a little fast traviling at passenger side of our 206 GTI he really love them. He also want same mods on his car. We started looking parts from everywhere. Scrap yards etc.etc. But we didnt find anything. My buddy thinking upgrade his car to ITB. And he decide sell 2.2 inlet manifold and throttle spacer our friend. After swapping parts on cars we are sad but our friend is happy. He did return to Belgium and install a exhaust header (i think raceland brand) on car. Then remap and He is more happy than we.
But news isnt good for we. Results of financal reason ITB prices is really high for us. And after looking www.206s16.fr site for 206 RC/GTI180 inlet and exhaust manifold swap and good results we decide try our change at scrap yard research againg. After very long research on different scrapyards finaly we found RC/GTI180 exhaust manifold. This is first part of our puzzle. Keep researching. And Viola. We found next part of we need. RC/GTI180 inlet manifold with electronic throttle body. We are close the finish. But last part is still missing. Gear selection cords. We need that because RC/GTI180 exhaust manifold need RC/GTI180 gear selection system for installation. Otherwise stock GTI gear selection rods is hitting exhaust manifold and is it imposible install lower traverse. We didnt find that part in 1 months. Because that part from 307 is to much longer. Brand new parts from Peugeot Service is really high price for gear selection system. But we have a friend. Also you know him. RCKid. Owner of Turbo 206 RC/GTI180 in Turkey. He already changed stock exhaust manifold for turbo manifold installation. And RC type gear selection system isnt protected from heating. Turbo and turbo manifold is generation to much heat and this is damaging gear selection systems small parts. So RCKid change his gear selection system to standart GTI bars. And we bought his system and that is all parts of puzzle. Last edited by Schumi on Thu Feb 24, 2011 5:10 pm; edited 1 time in total
#5: Re: 206 GTI with Highly Tuned engine (Pistons, Cams, Head, e Author: Schumi, Location: Istanbul / TurkeyPosted: Thu Feb 24, 2011 5:05 pm ----
And we bought stock 206RC airfilter box from an RC owner already installed and cold air intake.
And starting conversion of RC/GTI180 electronic TB to mechanical TB.
Some custom parts for TB is producing on CNC machine.
And that is bonus. We find this part on Fiat Scrap Yard.
Some shots.
And installation and settings. Let prediction which one is me.
And final. For the now.
#6: Re: 206 GTI with Highly Tuned engine (Pistons, Cams, Head, e Author: Schumi, Location: Istanbul / TurkeyPosted: Thu Feb 24, 2011 5:05 pm ---- And we change gearbox final drive with closed ratio one. That is really good modify. It is slightly incrise fuel consumption and lower your top speed but accelarating is amazing. My previous car have closed ratio final drive. And I really like them. But urban drive will bi noisy. Because you need more RPM for make same speed in same gear before.
Closed Ratio Final Drive 4.529
But after intake change our AFR need correction again. RC/GTI180 inlet is better than EW12 inlet. So we need another remap. And there is problem begining. Soldiring and desoldiring makes problem on ECU. After really hard job it get work. But not smooth. Engine stop sometimes. Its time to go standalone. Like any other mods its must be more DIY and cheap. Megasquirt is biggest opensource ECU project. And almost biggest comminity to get help. My buddy and also owner of this project 206 GTI is professional electronics. We bought un assambled kit. And short work assamble is complete. But base map will is hardest part. Anyway we get over all of them.
MegaSquirt3
Test Harness
#7: Re: 206 GTI with Highly Tuned engine (Pistons, Cams, Head, e Author: Schumi, Location: Istanbul / TurkeyPosted: Thu Feb 24, 2011 5:06 pm ---- Stage Three
After long test and tune days when we almost done everything and we are ready to go professional tuners for dyno tune. Its really really fast car. Without any fine tuning (actualy me and my mate do a safe map) his car serious faster than my stock 206 RC/GTI180. But an accident happen. Oil vapor pipe is plunged and engine suck a big amount oil. :( And result is broken piston ring segment. And we are started our real dream of several years.
What is our dream ? What are done ?
Jenvey ITB - Not Yet
Realy High Degree Race Camshaft - Not Yet
Better Clutch - Not Yet
High Compression Ratio Piston - At the now
Ported Polished Head - Already Done
4-1 Manifold, Catless, Stright Pipe Exhaust System - Alread Done
Standalone ECU, Wideband, EGT - Already Done
Closed Ratio Gearbox - Already Done
We choice Wössner pistons. But we didnt like wössner catalogs offer for 206GTI. And we take a risk and bougt 206RC/GTI180 pistons. That actual 12.5 CR but in 206 GTI cylinder head that nearly 14 CR. After pistons arrived our garage start rebuild engine with our helps. All painting jobs done by car owner.
Pistons
Last edited by Schumi on Thu Feb 24, 2011 5:14 pm; edited 1 time in total
#8: Re: 206 GTI with Highly Tuned engine (Pistons, Cams, Head, e Author: Schumi, Location: Istanbul / TurkeyPosted: Thu Feb 24, 2011 5:06 pm ---- GTI180 Inlet Manifold Gasget on GTI138 Engine Head
See difference. Ported and polished for match.
Idle Control Valve
Engine Rebuild
Painted Intake Manifold and TB and Fuel Rail.
Corvette LS2 Ignition Coils
444cc Injectors
#9: Re: 206 GTI with Highly Tuned engine (Pistons, Cams, Head, e Author: Schumi, Location: Istanbul / TurkeyPosted: Thu Feb 24, 2011 5:06 pm ---- Engine rebuild and running new engine is complete a while ago. But my mate moving new home. And before moving new home need alot of repair etc.etc. So he doesnt have to much time. Car is using daily at the moment but not completed hard tune. We did have problem with engine knock again. Actualy this is expected with that compression ratio (14) but we handle with standalone ECU. After March we took car to dyno tune with race gas (105 octane) for higher ignition advance.
Maybe this summer we will try install race bike ITB or maybe (maybe mean money :)) jenvey ITB.
Short list
MegaSquirt 3 ECU
AEM Wideband Air/Fuel Ratio
Port Polish Headers/Manifold Ports
206RC Inlet Manifold
206RC 70mm Butterfly
206RC Headers
206RC Gear System + Short Shift
444cc Enjektör
70mm Custom Cold Air İntake Kit
KentCams PT60 Camshaft
63mm Header-back Exhaust System
17x77 (4.529) Short Transmission
Removed EGR valve
There is nothing suspension or brake upgrade except lowering spring (yet). His and mine car expectation is to much different. (my car stock engine with suspension and brake upgrade)
I know this is long story but i forget a lot of thing. And alot of custom work. You can feel relax when you asking question.
Bonus.
3 years ago my mates getin married. And his wedding car.
2 years ago i am married. Any my wedding car.
#10: Re: 206 GTI with Highly Tuned engine (Pistons, Cams, Head, etc) Author: Addaz, Location: SuffolkPosted: Thu Feb 24, 2011 5:14 pm ---- Lovely work
I would love to have some of your tools one day
#11: Re: 206 GTI with Highly Tuned engine (Pistons, Cams, Head, etc) Author: Seabook, Posted: Thu Feb 24, 2011 5:19 pm ---- would be interesting to see RR figure too.
#12: Re: 206 GTI with Highly Tuned engine (Pistons, Cams, Head, etc) Author: Schumi, Location: Istanbul / TurkeyPosted: Thu Feb 24, 2011 5:21 pm ----
Seabook wrote:
would be interesting to see RR figure too.
I will upload them but i cant find my copies. I will get a new copy from dyno owners.
#13: Re: 206 GTI with Highly Tuned engine (Pistons, Cams, Head, etc) Author: Lee., Location: Blackwood, South WalesPosted: Thu Feb 24, 2011 6:32 pm ---- Outstanding work, true commitment!
Please carry on with the updates!
#14: Re: 206 GTI with Highly Tuned engine (Pistons, Cams, Head, etc) Author: Nimminz, Location: Durham, NE England, UKPosted: Thu Feb 24, 2011 6:45 pm ---- like it mate!! Megasquirt looks all well done!
#15: Re: 206 GTI with Highly Tuned engine (Pistons, Cams, Head, etc) Author: MutilateTheDead, Location: DerbyPosted: Thu Feb 24, 2011 7:37 pm ---- VERY nice!!! wish i had the time, tools and money to do something like this
#16: Re: 206 GTI with Highly Tuned engine (Pistons, Cams, Head, etc) Author: =ZiAn=, Location: SloveniaPosted: Fri Feb 25, 2011 8:38 pm ---- Nice project man BTW why don't you make your own custom ITBs? You can make them smaller (not the diameter of course) fit perfectly on the existing intake manifold and with access to CNC a lot cheaper Just a suggestion though.
#17: Re: 206 GTI with Highly Tuned engine (Pistons, Cams, Head, etc) Author: Schumi, Location: Istanbul / TurkeyPosted: Sun Feb 27, 2011 5:33 pm ----
=ZiAn= wrote:
Nice project man BTW why don't you make your own custom ITBs? You can make them smaller (not the diameter of course) fit perfectly on the existing intake manifold and with access to CNC a lot cheaper Just a suggestion though.
Thank you. I hope you enjoy that. And ITB. Some of our friend tried make custom ITB on CNC (toyota 4age and Saxo VTS) but result didn't satisfy. We will try some options. (Complete custom or bike + custom).
#18: Re: 206 GTI with Highly Tuned engine (Pistons, Cams, Head, e Author: Kersh, Location: Bridgnorth, Nr WolverhamptonPosted: Wed Mar 02, 2011 5:22 am ---- great read!
make and sell me one of these please
i want a 180 inlet!!
#19: Re: 206 GTI with Highly Tuned engine (Pistons, Cams, Head, etc) Author: Schumi, Location: Istanbul / TurkeyPosted: Thu Mar 03, 2011 1:20 pm ---- This flange for EW12 inlet. Do you want use your stock TB with 180 inlet ? Stock TB is so small for 180 Inlet. I suggest to you Honda B16 / K20 TB with flange or Clio RS172 TB with flange.
Ofcourse you have another choice. Use 180 TB. But as you seen there is so modification needs for convert electronic TB to mechanical TB.
#20: Re: 206 GTI with Highly Tuned engine (Pistons, Cams, Head, etc) Author: PugJH, Location: NorthantsPosted: Thu Mar 03, 2011 1:59 pm ---- MENTAL what with the cost of cars and parts out that way, but you got a head start with all them tools.
Thank you. I hope you enjoy that. And ITB. Some of our friend tried make custom ITB on CNC (toyota 4age and Saxo VTS) but result didn't satisfy. We will try some options. (Complete custom or bike + custom).
Do you know what went wrong with the custom ones? We're building them for my project so I'd like to get as much information as possible
#22: Re: 206 GTI with Highly Tuned engine (Pistons, Cams, Head, etc) Author: Schumi, Location: Istanbul / TurkeyPosted: Tue Mar 08, 2011 1:26 pm ---- IIRC general design problem. As you know turbulence needed at inlet manifold. Wrong design can give high fuel comp. but loss or same power.
#23: Re: 206 GTI with Highly Tuned engine (Pistons, Cams, Head, e Author: wifey, Location: The MoonPosted: Wed Mar 09, 2011 4:15 pm ---- really good read thank you for taking the time to put it all o nthe forum
regards
#24: Re: 206 GTI with Highly Tuned engine (Pistons, Cams, Head, e Author: murat, Location: TurkeyPosted: Fri Mar 25, 2011 5:23 am ---- nice project
#25: Re: 206 GTI with Highly Tuned engine (Pistons, Cams, Head, e Author: Schumi, Location: Istanbul / TurkeyPosted: Fri Mar 25, 2011 1:18 pm ----
murat wrote:
nice project
Ehehe. Everyone. That my best friend. Its owner of that car.
#26: Re: 206 GTI with Highly Tuned engine (Pistons, Cams, Head, etc) Author: Schumi, Location: Istanbul / TurkeyPosted: Wed Jul 13, 2011 2:53 pm ---- Video Added. Rolling with Saxo VTS (just filter and exhaust.)
#27: Re: 206 GTI with Highly Tuned engine (Pistons, Cams, Head, etc) Author: Vengel, Location: BulgariaPosted: Fri Jun 08, 2012 6:03 am ---- hi
i have ew12 intake manifold in my garage.
my question is - if I install the int.manifold + flange + Clio TB, do i need new a/f ratios or any other modification ?
or is it just bolt on with these 3 parts and that`s it ?
i`m currently looking for clio rs tb and I`m not sure if there will be cable work needed. is there any plugs to consider?
#28: Re: 206 GTI with Highly Tuned Engine - 13.07.2011 Video Added Author: Schumi, Location: Istanbul / TurkeyPosted: Fri Jun 08, 2012 7:39 am ---- I dont know Clio RS TB. Maybe a little cable work needed. But cable must be your last consider. What about TPS. I think it didnt compatible with stok ECU. And you need complete new AFR. It have to be custom remap. There no generic map can work with that setup.
#29: Re: 206 GTI with Highly Tuned Engine - 13.07.2011 Video Added Author: spike_202, Location: West midsPosted: Fri Jun 08, 2012 7:40 am ---- Lol looks like the saxo was going backwards good work mate
#30: Re: 206 GTI with Highly Tuned Engine - 13.07.2011 Video Added Author: 206gt160, Location: BlackburnPosted: Fri Apr 19, 2013 1:01 pm ---- Do you need to use the oiler cooler on the inlet.. If that's what it is? Or can it be left disconnected? I'm on about the detachable part on the back of the inlet with 3 pipes inlet/outlets on it??
#31: Re: 206 GTI with Highly Tuned Engine - 13.07.2011 Video Added Author: heyziq, Location: MalaysiaPosted: Sat Feb 08, 2014 2:54 am ---- mate opening old thread, what icv you guys using, im wondering
#32: Re: 206 GTI with Highly Tuned Engine - 13.07.2011 Video Added Author: Schumi, Location: Istanbul / TurkeyPosted: Mon Feb 10, 2014 5:49 pm ---- It was stock ICV with 306 GTI6 ICV housing.
#33: Re: 206 GTI with Highly Tuned Engine - 13.07.2011 Video Added Author: JamieM, Posted: Tue Feb 11, 2014 7:37 am ---- Looks good alot of work gone in to that by the looks of it. Was it a 1.4 vts or 1.6 vts? and what mods if any was it running to get beaten by the 138 let alone that bad?
138 must be pretty rapido to beat a 1.6 vts especially if it was modded as well! How does the 138 fair against a stock 180/rc?
My old breathered 1.6 vts was as quick if not quicker than my 180 which is no slug compared to at least 2 other 180's I've played with.
#34: Re: 206 GTI with Highly Tuned Engine - 13.07.2011 Video Added Author: heyziq, Location: MalaysiaPosted: Wed Feb 12, 2014 7:28 am ---- stock 206 gti 138 icv ???
#35: Re: 206 GTI with Highly Tuned Engine - 13.07.2011 Video Added Author: 206gt160, Location: BlackburnPosted: Wed Feb 12, 2014 1:07 pm ---- 306 gti6 icv is what I used
#36: Re: 206 GTI with Highly Tuned Engine - 13.07.2011 Video Added Author: Misio, Posted: Mon May 12, 2014 5:04 am ---- I want to install ew12 intake manifold into my GT with adapter and then go for a remap. Can u tell me what will happen with fuel consumption and low revws ?? Will it get back to normal after remap ? I have atm ebay 4-1 exhaust manifold...
#37: Re: 206 GTI with Highly Tuned Engine - 13.07.2011 Video Added Author: Schumi, Location: Istanbul / TurkeyPosted: Tue May 13, 2014 4:56 pm ---- Your middle rpm range will be very powerful after EW12 intake. I cant remember low revs but RC intake make low revs unhappy. But EW12 intake have longer runners and thats good for lower-middle rpms. So it has to be no problem on low revs. Just you need good remap.
#38: Re: 206 GTI with Highly Tuned Engine - 13.07.2011 Video Added Author: Misio, Posted: Tue May 13, 2014 5:41 pm ---- Can u tell me something about fitting that intlet into 206? I see u had no problems with that but friend of mine told me that there are problems with radiator...
#39: Re: 206 GTI with Highly Tuned Engine - 13.07.2011 Video Added Author: Schumi, Location: Istanbul / TurkeyPosted: Wed May 14, 2014 4:05 am ---- Yes radiator will be your problem. Inlet is touching radiator. You need to modify radiator fixing points of lifting engine back (or front I cant remember) a little from engine mounts for clearance. Both one will be preferred.
#40: Re: 206 GTI with Highly Tuned Engine - 13.07.2011 Video Added Author: Misio, Posted: Wed May 14, 2014 5:34 pm ---- Can u tell me something more about modifing radiator fixing points ? Any clues ?
#41: Re: 206 GTI with Highly Tuned Engine - 13.07.2011 Video Added Author: PezHdi, Location: ShrewsburyPosted: Mon Sep 01, 2014 5:33 pm ---- Any up dates on this schumi?
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General
First all of we need referance point. Go to dyno.
:( And result is broken piston ring segment. And we are started our real dream of several years.
BTW why don't you make your own custom ITBs? You can make them smaller (not the diameter of course) fit perfectly on the existing intake manifold and with access to CNC a lot cheaper 
