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Before You Begin:
The
best possible base for this sort of conversion is the 1.6/1.9 Gti?s. The only
difference being is that the 1.9 has the rear brakes! Having said that, it is
in your interest to avoid pre ?87 non-Gti models such as the 1.1 because they
have different inner wings that will need to be modified? it just isn?t worth
the bother. Avoid using the XS model fitted with the TU engine and drive-train.
A swap of tedious proportions will be on your hands since nothing is of use at
all; the engine, gearbox, driveshafts, the whole malarkey needs swapping. You
are better off finding an oil burner with the XU engine as you could at least
use the gearbox! Don?t forget, if you opt for a non injection model and you
want to run the standard Mi16 injection, you?ll need a suitable fuel pump.
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Choosing
your weapon!
Mi16 engines are not
only fitted to the 405Mi16, but also to the Citroen BX Gti from ?87 ? ?92. They
are the same engine. However, the BX uses slightly different variation on
induction, so you?ll have to swap it for the Mi16 unit. Also, the BX?s ECU is
mounted under the front seat so you have a longer loom to cope. There are also
variations on the Mi16 theme; cars registered with a k-plate onwards had a
variable length inlet manifold. It doesn?t mean any extra power, but it does
mean more torque at lower revs. The downside to this,
is that there?s more pipe work to sort out since the system runs off the engine
vacuum. The latest suitable engine is the XU10J4RS, the Gti-6 from the 306
which pumps out 167bhp as opposed to the 150bhp of the Mi16. It also needs more
plumbing and costs a bloody shed load.
More
power once it?s in? If
you find that you?ve got used to the extra gee gees, then here?s how to get a
bit more power. Junk the standard Mi16 injection in favour
of a lovely set of 45 carbs on the appropriate manifold. You?ll need to junk
the central computer, and remove the engine management system and screw a
distributor on the end of the head. Fit a fuel regulator to restrict the fuel
injection pump. Swap the cams for a set of
What about wiring the bloody thing up?
BX
Wiring Instructions! The
word document below details (as accurately as we have at the moment), how to
wire up the BX wiring loom to the 16v engine. This information has kindly been
donated to me but we take no responsibility for any damage that this may
course. It is purely for reference and should at least help you get started. If when downloading it comes up with password/user name,
just press cancel and the document will open up.
How the hell?s it done then?
405 Mi16
engine into the 205/309! Everyone
has heard of this conversion. It?s got to be the most popular and easiest
conversions going and gives the Pugsley a mush need
kick up the arse in power. Because I?ve had so many enquiries on how to do the
conversion and save a shed load of money as well? below is all you need to
know!!! Sit back and enjoy.
Dash
Board! You will be glad to
know that you can keep the standard 205 Gti dashboards since all the sensors
from the Mi16 engine will hook straight up. Earlier 205?s (the square dashs before f-reg) are slightly
harder though.
Chassis! As long as you do it
correctly and don?t rush the job, there should be no modifications to the
chassis. The exhaust WILL catch on the back of the bulkhead, but if the bottom
engine mount is altered then there?s no problem.
Engine
Mounts! The Mi16 engine is
basically the same engine as the 205?s 8v with a different head and twin cams.
All the mounts from the Mi16 engine should fit straight onto the 205. However, the
bottom mount needs to be extended to swing the engine forward slightly
providing some much needed clearance for the exhaust. Take care that it?s not
too much, as this can cause extra strain on the driveshafts leading to early CV
joint failure.
Air Filter!
Fit a lovely new K&N filter onto the end of the air-flow meter. As
far as I know, there isn?t a filter readily available so you can always use the
one intended for the Rover V8!
ECU! There are a couple of
different types of Mi16 ECU. The pre ?91 uses two rows of pins and has a
different management system. It?s more upto date but doesn?t offer any benefits
in increasing power. It does however have a knock sensor to control detonation.
Make sure that you get the complete system for the car ? don?t mix and match.
You can fit the Mi16 ECU in the original 205 position under the scuttle panel,
routing the wiring over the dash.
Exhaust! You can retain the
original Mi16 exhaust manifold but tilting the engine does make it hand a lot lower
making it easier to catch on speed humps. If you can?t live with this, then fit
a tubular exhaust manifold supplied by Pug Performance and you can do away with
the modified mounts too.
Gearbox! There are a couple of
choices for the gearbox dictated mostly by the way you drive. By preference,
use a 205 ?box. The Mi16 is a little bit long-legged and you won?t get as much
performance. If you really want to fly/acceleration, then fit a 1.6 box. If you
want all round acceleration and better cruising, then the 1.9 is the one to go
for. Whatever you do, make sure that you get a post ?97 gearbox with a crank
trigger for the ignition otherwise you?ll need to fit a distributor.
Wiring! A good thing about the
earlier cars was that all the wiring was in one place. Later models used
separate wiring looms for the engine and the management? one?s routed
differently to the other! You need to remove the old 205 loom
and replace it with the one from the Mi16 but you?ll need to strip the sensors
out of the old and fit them into the new. Once this is done,
route the lot through the right-hand side top corner of the bulkhead, which is
the method used in the early 205?s.
Clutch Use the bigger Mi16
clutch and flywheel. Watch out for the release bearing. You need to know which
box you have ? cars upto 1989 used the BE1 gearbox needing a BE1 release. Later
models used the BE3, which will obviously need the corresponding release
bearing. All linkages hook upto all boxes.
Cooling Retain the standard
cooling system, but shift the radiator forward into the fan box. This then
allows clearance for the fuel injection system. It is still very close so make
sure there?s clearance for both the plenum and the fans. Hooking up the engine
requires a post ?91 heater hose which is longer crushing the need for make
shift joins in the system. Also, use a T-pierced Citroen BX bottom hose as
don?t forget, you want the thing looking professional.