#121: Re: 206 GTI 180 Rally car project Author: imjeeves, Location: Glasgow / WellingPosted: Fri Mar 18, 2011 3:07 am ---- I am not 100% sure where it was bought from as I bought it from Jamie who is on here. I think he bought them from the Jenvey direct.
My manifold does not clear the PAS pump either once the filter is fitted for the TB. This could be because ITG made a specially built box for rallying and to increse torque. It is quite a bit bulkier than just a normal filter I think
To overcome the PAS problem I used the electric pump from a 106. It stops any power being zapped by the PAS pump as well.
No i dont have a servo on my car so I did not need to take a tap into the inlet manifold. I have seen it done though and dont think it would be too difficult to do.
Is it the 180 or 138 engine? If its the 180 then you need to make up oil drains as well.
#122: Re: 206 GTI 180 Rally car project Author: briant, Location: IrelandPosted: Fri Mar 18, 2011 8:27 am ---- Cheers for reply,Mine is 138 i was thinking of going down electric pump route too or fitting a remote resevoir to existing pump,
Your car is coming along very nicely ,with some luck i might get mine fired up next week have most of looms finished just a few bits to tidy up.
#123: Re: 206 GTI 180 Rally car project Author: macj, Location: EssexPosted: Fri Mar 18, 2011 11:18 am ---- Fit the Vauxhall astra P/S pump and remote reservoir from the 205
#124: Re: 206 GTI 180 Rally car project Author: Schumi, Location: Istanbul / TurkeyPosted: Fri Mar 18, 2011 4:31 pm ---- I prefer 307 - C4 electric PAS with onboard reservoir.
#125: Re: 206 GTI 180 Rally car project Author: imjeeves, Location: Glasgow / WellingPosted: Fri Mar 25, 2011 7:58 pm ---- Car is getting mapped tomorrow. Can't wait to see what she puts out. Will take some pics / videos to upload
#126: Re: 206 GTI 180 Rally car project Author: imjeeves, Location: Glasgow / WellingPosted: Mon Mar 28, 2011 2:59 pm ---- Well went to the rolling road on Saturday and had a bit of an strange day really.
Got the rolling road and the electricity company had decided to cut all electrical power to the place. So we set up all the throttle bodies etc and that was ok.
Strange hissing from the throttle bodies when we switched it off. Turns out i forgot to leave an inlet in to atmospheric air and this was pressurising the sump and pushing oil into the exhaust. So i took one of the oil pipes off and that sorted that out.
Then put it on the roller and had some issues with the VVT system. I though that the emerald ecu could cope with the VVT but apparently it cannot. Emerald can only switch the VVT on or off which is not suitable.
SO
I have had to buy a DTA ecu which can vary the VVT dependent on the cam position. Even without the engine running right I managed to get 194bhp which is ok but with the DTA system it will bw well over 200 So another trip to the rolling road soon and another light wallet needed
#127: Re: 206 GTI 180 Rally car project Author: Schumi, Location: Istanbul / TurkeyPosted: Tue Mar 29, 2011 10:59 am ---- Did you ever get on dyno when car is stock ?
#128: Re: 206 GTI 180 Rally car project Author: macj, Location: EssexPosted: Tue Mar 29, 2011 11:09 am ---- Thats a good result for an engine thats not on song..... will look forward to see what the end result is..... Very interesting about the emerald ECU and VVT.... They told me they could handle the 206 180 engine no problem..... seems they were a little shy on the truth. I have been in discussions with Newman Cams today.... they produce a 280 profile that seems right up our street.... would need to dump the VVT in your case though but at £350+vat a pair its good news
Where have they set the limiter BTW??
#129: Re: 206 GTI 180 Rally car project Author: simpsonrc, Location: coventryPosted: Tue Mar 29, 2011 4:51 pm ---- hi with the oil venting problem is this to do with the jenvy manifold blocking off the two oil breathers on the head where they vent in to the standerd inlet manifold? im just try to work out what to do with these on mine. thanks
#130: Re: 206 GTI 180 Rally car project Author: Edward, Location: In the garagePosted: Wed Mar 30, 2011 12:35 am ---- I'd drill the manifold and fit an adaptor with a hose linking back to the sump. Why does the 180 has these two holes???
#131: Re: 206 GTI 180 Rally car project Author: imjeeves, Location: Glasgow / WellingPosted: Wed Mar 30, 2011 1:10 am ---- No never had that engine on the dyno before the mods but I recon it will have been around 170bhp max. I don’t think they are actually 180bhp.
Cams would be the way to sort the problem as that would give it the high lift cam that effectively the VVT system is doing. I have already bought the DTA ecu the other day so I need to stick with the original plan of standard cams and VVT system working correctly.
The guy at the rolling road was really good he explained how the VVT system works and the background to it. Basically Peugeot could not get 180bhp from that engine and so gave it to Lotus to develop. They had a tie in with Toyota at the time and basically they just fitted the Toyota VVT system to the GTI with a few other mods to the engine to cope with it all.
Think I am going to call Emerald today and tell them that it doesn’t work as they said it would work fine. Clearly they don’t know / don’t want to admit it’s only the Honda system that it can cope with.
Limiter was set at 7500rpm I think
SIMPSONRC:
Yes that was the problem that I had.
Just as Edward said you need to drill the manifold and fit an adapter.
Ok so the way to fit it is to drill into the manifold where the existing holes were on the block. Hole doesn’t need to be the full size of the original just enough to slide a piece of metal pipe in. Then metal filler / weld the pipe into the manifold. Fit a pipe to both sides with two t-pieces down into the sump with a takeoff to the head and also to atmosphere / catch tank.
EDWARD: The reason for these holes are that the oil in the head of the 180 for the VVT system cannot drain to the sump fast enough. As the VVT advances it requires more oil than the standard GTI and as it retracts the VVT it cannot without the drain loose the oil pressure in the head. There are two situations. It can pressurize the head and eventually blow the oil out the cam cover gasket or in my case pressurise the sump. What it was doing was pressurising the sump and at idle it was pushing oil up through the bores into the exhaust. Hence the hissing coming from the throttle body trumpets.
#132: Re: 206 GTI 180 Rally car project Author: 206rally, Location: DurhamPosted: Thu Mar 31, 2011 3:06 pm ----
Edward wrote:
I'd drill the manifold and fit an adaptor with a hose linking back to the sump. Why does the 180 has these two holes???
I drilled the 2 holes in the inlet manifold, tapped them and put in air fittings then pipes to std breather system on mine. Had no problems with this in the 5 years i've ran the 180 engine on jenveys.
Shame about VVT, but have never used mine since putting cams in.
car build looks good.
Mark
#133: Re: 206 GTI 180 Rally car project Author: imjeeves, Location: Glasgow / WellingPosted: Thu Apr 07, 2011 8:50 am ---- Ok so spent all the other night rewiring my perfectly good Emerald ECU and installing it to fit the new DTA S60 ECU that I have bought.
Drove all the way to the rolling road and the car wouldnt start. After 3 hours of messing about we got it started and ready for the rollers
Put it on and the cam senor came up with 86 errors. I presumed that I had wired it worng as I didnt really know the correct wiring for it. Three wires a live, earth and signal so I didnt think id get it too wrong! Turns out the sensor is broken. This was because I was testing with my 12v power probe when the sensor is only 5 volt.
Had to leave the car there are drive all the way back 2 and half hourse to pick up my spare which I presumed was also broken as I checked that one with 12v as well. It was broken so I had to steal a cam sensor out the 180 road car I have for parts.
Back down to the rolling road today and again more problems! The cam signals to the ecu were too close together so we had to try and make the ecu only read one every so often. Took all morning and part of the afternoon and finally got it on the rollers.
211BHP @7000rpm and 200 lb/ft torque happy days
#134: Re: 206 GTI 180 Rally car project Author: macj, Location: EssexPosted: Thu Apr 07, 2011 9:46 am ---- good result mate.... welcome to the wonderful world of aftermarket ECU`s.... always seems to be something to trip you up... glad you got it fixed
#135: Re: 206 GTI 180 Rally car project Author: imjeeves, Location: Glasgow / WellingPosted: Fri Apr 08, 2011 2:38 am ---- Yeh I was happy with the result as I doubt the car is actually 180 bhp as standard. Over 31bhp gain on a standard engine is really good
We are not responsible for comments posted by our users, as they are the property of the poster
Interactive software released under GNU GPL,
Code Credits,
Privacy Policy
Membership:
Latest: 
New Today: 0
New Yesterday: 0
Overall: 17129
Online Now [150]:
Visitors: 149
Members: 0
Staff Online Now:
Page Views:
General
So another trip to the rolling road soon and another light wallet needed 
