(605) Peugeot 605 2.0 16-valve 350HP Project

Hello again!

I am proud to be the first international member on this forum!!!

My car is Peugeot 605 2.0 8v Turbo.... It would have been better if I would have said "IT WAS ..."

The engine was too weak – XU10J2TE, 143 HP @ 5500 rpm and 235 Nm @ 2500 rpm. So I decided to tune my engine for high street performance.

Firstly I decided to move from 8v to 16v, or let say something similar to XU10J4TE, using cylinder head from Peugeot 306 2.0 S16. Most probably some of you know that this head was installed for the first time in Pug 405 T16 and was mainly developed for turbo applications. The good news was that all XU10 engines share the same engine block and crankshaft. The camshafts are very mild for turbo engine - 230° and 9mm lift.

My HP target was about 300-320 HP @ crank, because the car is front wheel drive and I will have launching problems with more HP and torque. Neverthless, later on I changed the turbo and my target did raise to 350 HP.

So I bought brand new turbocharger Garrett GT2860RS. With his wide compressor map it is very suitable for my project.

I had to modify the lower part of the engine. I ordered custom JE pistons and custom Pauter rods from Top-End Performance, thanks to Steve.

I wanted to useCometic Phuzion MLS gasket with Gas-filled O-rings, but later on I found that pretty good multi layer gasket was available in Peugeot store.

A new custom exhaust 4-1 manifold was produced. Originally the turbocharger was situated behind the engine. The space is very very limited and it was impossible to fit the bigger turbo and 4-1 manifold. So I decided to move the turbo to the side of the engine, right above the gear box.

A custom divorced downpipe will be produced soon, separating the main gas flow from the turbine and the gas flow though the wastegate in order to minimize the turbulence. I wanted to make it with two separate and independent exhaust tubes and mufflers, but I am limited again with the available free space under the bonnet.

SPEC Clutches and Flywheels agreed to produce a custom Stage 3+ clutch kit for my car. The problem was with the splined hub. My main gear shaft is was with 21T x 24mm – the same like many Toyota Corolla, Cellica, MR2, etc. So they will remake one kit for Volkswagen Golf VR6 but with Toyota’s splined hub. I will order the kit as soon as I get my car on the road. For the time being the original clutch is installed.

As regards to the ECU, I bought Haltech E8 ECU with 3-bar MAP sensor, full pack of three sensors – TPS, air temperature and coolant temperature, boost solenoid and trim module.

In additional I bought Innovate LC-1 wideband controller with gauge.

I ordered intercooler core, end tanks, silicone hoses and clamps from a USA company named "VECCO"... NEVER DEAL WITH THESE GUYS!!! Thanks God I received them AFTER 3 MONTHS MAYBE, there was time when I thought I would never receive them.

I ordered the intercooler separately to remake the end tanks. I use vertical flow core, so in order to improve the intercooler performance and for even distribution inside the core. I added two deflectors.

I bought HKS SSQV Blow-off valve with aluminum flange that will be welded directly to the 2.5” tube.

For the fuel delivery system I bought BOSCH fuel pump that delivers up to 160 l/h and up to 6.5 bar fuel pressure. The pressure will be regulated by an Aeromotive fuel regulator.

The stock brakes were be modified too. I bought two brand new front rotors from Alfa Romeo 166 3.0 v6 – 310mm/28mm. They fit perfectly to my wheel hubs. I bought slightly used calipers, again from Alfa Romeo 166. They are 4-piston calipers with huge brake pads.

I will post some pictures soon.

Greetings to all of you

Mike

Towa beshe nachaloto:



Smenih wsichki amortisiori s KONI Red Special:

Posle rekoh da naprawia port & polish na glawata i otworihme dwigatelia .... PROBLEM:

1. Cilindrite biaha za osnowen remont:





2. Glawata se okaza spukana na 2 mesta:




..... triabwashe da se naprawi remont ...

Pochnah da diria nowa glawa - PAK PROBLEM - ne mozah da namera 8v glawa pod 200 EUR w Bulgaria ... no namerih 16v ot Citroen ZX Voulcano!!!






Ot towa grozno pate stana edin krasiw lebed:

Na dnewen red doide remonta na cilindrowia blok.

Porachah butala JE Pistons i biel Pauter po moi project:

Remontirahme cilindrowia blok:
























Towa otdiasno sam az :








Wsichko towa beshe montirano w bloka:








Wzehme nowa gasket ot Peugeot GTi6:

Great work my man keep up the good work and keep us posted....

Bravo majstore. Ti i Damzda da se udruzite i ima da napravite 6055.

Dwigateliat beshe postawen na kolata i ia zakarah w moia garage:




Pod kapaka imashe kakwo li ne!!!! Edna topka ot prowodnici!!!






Hwanah se i mahnah wsichko izlishno:

doko ::

Great work my man keep up the good work and keep us posted....

No problem, that's what I am doing right now. :P

xenoks ::

Bravo majstore. Ti i Damzda da se udruzite i ima da napravite 6055.

Az sam narekal moia project "Peugeot 6005 16v Turbo".

Misho is building 6005;)

there is still more pics to come ...
this was only the beginning as i am informed.
just be patient ...
i like that custom peugeot detail on piston rod;)

Taka, sled towa se zahwanah s intercooler i radiatorite.

Intercoolerat go kupih razgloben:








Posle go prerabotih i mu slojih razdeliteli watre w kranite kazancheta:









..... i stana towa:

dandzaman ::

... just be patient ...

Yes, be patient ... I am doing my best.

Kolata otpred beshe taka:




Wsichko beshe preraboteno, za da moje da se slozi nowia intercooler, kakto i da premestia ventilatorite zad radiatorite ...








Znaete li kakwo e disekcia? Eto kakwo e:







Poluchi se eto towa:





Wednaga beshe montirano na kolata i zapochnah da napaswam radiatorite:

Zapochnah da montiram tiurbo trabite:












Posle leko dobawih edni stoiki za intercoolera i go slojih na miasto:

Za intake manifold izpolzwah gotow ot Peugeot 405 Mi16, a wzeh droselowa klapa ot Peugeot 306 S16.

Poneze droselwoata klapa stawa perfektno na flaneca na moia originalen intake manifold ot 8v dvigatelia, naprawo otriazah flaneca:

How far away are you from ending the project in relation to time?

chorba ::

How far away are you from ending the project in relation to time?

and when you finished work show same pictures and give some informations, some numbers
0-100 km/h, 0-200km/h, 0-300km/h

gigant ::

chorba ::

How far away are you from ending the project in relation to time?

and when you finished work show same pictures and give some informations, some numbers
0-100 km/h, 0-200km/h, 0-300km/h

0-300 .... The max speed limit will be up to 260 km/h, the gearbox does nto allow me higher speeds .... moreover, I am not so brave to drive with 300km/h.

There is no dead time. I was out for money for a few months. I did earn some money recently, and I moved a little bit to the end of the project. I will post some pictures today.

Firstly, I replaced the previous turbocharger Garrett GT2860RS with something better ... and bigger:























The new turbo demanded new external Wastegate TiAL F40:

New italian suction type fans were ordered:

Of course, a proper exhaust manifold were purchased from DP-Engineering:


















The manifold was ordered unfinished, because it had to be modified here according to the available free space in front of the brake pump.

The dashboard was remastered, as well totaly new stand was produced for the additional gauges.

New front suspension was installed.





SPAX springs and KONI Special shock absorbers





I managed to find second hand 4-piston BREMBO calipers and BREMBO brake rotors from Alfa Romeo 166 3.0 24V.