Bram's CTi T16 conversion

One moment you’re starting a search for a crashed Peugeot 205 GTI for one of your friends and the next moment you end up buying a 205 CTI for yourself. ??? Yes that’s what I’m thinking as well. But fortunately a bit later I found a 205 GTI for my friend as well. So now I have two 205’s that need repairing….. Ah well it’s a way to keep someone of the streets. But when they are finished I believe the result won’t be a sight for sore eyes.

Anyway as I was saying I started searching for a 205 for one of my friends. So the moment Mac called me that he knew where to find a crashed 205 CTI that wasn’t very expensive I drove to the south part of Holland to take a look. The car was built in ’91 and had a full-leather interior, power steering, electrical roof and (according to the salesman) a 1.6 engine. But taking a look at the paper s learned that it was in fact a 1.9 (talk about being lucky).

	At first sight the damage appeared to be reasonable, but after taking a look underneath the bonnet I realized that there was more damage than expected. So repairing would involve more than mounting a new bonnet, bumper, headlight and things like that. At that point I started doubting (not because I couldn’t fix it, but because of the amount of work involved).

I drove back home in order to discuss it all with my friend and after that conversation and some more thinking called Mac with the announcement that I was going to buy the car. Mac arranged the down payment for me and made sure that the car would be delivered at my house. That saved me a ride or two up and down to Limburg (province of Holland). Since I had to make some space for the car it would be delivered after two weeks. Then something completely unexpected happened. From the moment I started driving a 205 GTI I began searching for a 405 T16 engine. After a lot of rather intense efforts I gave up hope of ever finding one. At that point I decided to use a “normal” 2.0 16V engine without a turbo (see my 2.0 16V conversion story) and transplanted that power-plant in my GTI. But that was way before I bought the convertible. Now I was impatiently waiting for that car. Somewhere during the time I was waiting the word T16 passed again in an email conversation (or not Hilgert?). And just for fun I restarted my attempts to find a T16 engine. For fun because I never dreamed of finding one. Hilgert made a lot of phone calls for me (even in France) in order to find one. The first few days that seemed to be futile (as expected), but not much later I got the amazing news that he found one. The best part was that the engine was in my own country. Talk about being lucky!! Then you’re asking yourself the question if it is a real T16 engine and not a 2.0 8v Turbo or something like that (you’ll be surprised how easy a junkyard tells you that they have what you need). So in my highest gear I went over there to take a look so that I wouldn’t be disappointed that the engine was sold. After arriving at the junkyard (and overcoming being scared by the guard dog) I came to the conclusion that it was a real 405 T16 that was standing there. There wasn’t even much wrong with the car. Only a dent in the trunk and a damaged alloy wheel. So sending the car to the eternal hunting fields seemed a bit of a waste. But importing the car would cost a lot as well (it was not a registered Dutch car). So at that moment you are standing there looking at a engine that looks the bullock….. What are you going to do…… do you buy the engine or not?

If you are a Pug freak like for instance me you don’t have to think about this. There isn’t any room for thinking about it and you will never ever think about it. After more than 5 years you find the engine you always wanted and then you don’t buy it???? No don’t think so. So I bought the engine.

Okay now you’re stuck with a GTI, CTI, a 1.9 CTI engine, a 2.0 16V S16 engine and a 405 T16 engine. Pretty much isn’t it? At least that is what I thought and since I haven’t got the means to produce money without having to work for it some of it had to be sold in order to finance things. I know of myself that I have a pretty strong heart (it still works after almost 24 years even with my lifestyle) but to sell my GTI… No that wasn’t an option (although I thought about it for a while). The CTI engine? Yes would be nice, but wouldn’t bring enough money. And besides that finding a person who wants such an engine would probably take more than a short while. So in the end only one option stayed open (although I rather wanted to keep it) and that was to sell the also hard to find 2.0 16V S16 engine. But what had to be done needed to be done. But the engine was still in the blue GTI. Since I needed a car it wouldn’t be handy if I couldn’t use the car for a while. But nobody ever managed to do a engine conversion just by looking at the car and the engine, so I had to find a solution for that. In the meanwhile a CTI is standing in your garage as well and a convertible seems nice as well. And then you start thinking!! Your brain is doing overtime and you come up with the idea of doing something nobody (or very little people) has done before. Mount the T16 engine in a CTI and try to fit 4-wd under it as well. This all explains immediately why I had to find another 205 for my friend. Sorry Denis, but I made up for it in the end, didn’t I?! Since I have very little spare time, it is difficult to make appointments with people to remove the 2.0 16V S16 engine. That is something I don’t like as well (or am I Mac?). I never seem to have enough time. Anyway I had a appointment with someone to help him with his 205, but he cancelled that appointment on the day itself. Since Mac was here as well and you don’t want to do nothing you start doing something else.

	So we started to remove the 1.9 engine out of the CTI. Everything still attached to it. We lowered engine, wheels, subframe, gearbox, driveshafts and more in one piece. It took less time then expected and in the mean while we got the idea remove the 2.0 16V S16 engine out of the GTI as well and besides that mounting the already removed 1.9 from the CTI in the GTI.





	Yes we really managed to do that. After amany hours both the CTI and GTI were standing on 4 wheels again ( the CTI without an engine though). A few things had to be connected in the GTI so driving wasn’t an option yet, but the 2.0 16V S16 engine could be picked up by the new owner.

At this point the CTI is completely stripped (and with stripped I really mean stripped to the bone like the pictures are showing). Why? Well just isn’t my color and when the car is ready no red shall be found on the car. Besides that the chassis need some modifications and the crash damage needs to be fixed. If you don’t have to pay attention to, for instance your dashboard, when you are welding you can work faster and with more ease. Also I'm working on a few ideas as well but I will reveal those at the time they will be carried out (if they will be carried out). That’s what a hobby is al about!!!

At this moment I’m still collecting data about the T16. Mostly more information about the wiring, gearbox and things like that. Why the gearbox? Well the idea of putting 4-wd under the car is realizable (although with lots of effort), but involves a lot of modifications and money so this plan isn’t going to be realized (yet!). So I began comparing all the possibilities for gear ratios in order to make a nice gearbox for the T16 engine (see also the tech. story “Gearboxes” on this site for more information about gears). Once again thanks Hilgert for the acquired T16 info from a dealer in Holland. I’m also still in search for the right electrical schemes in order to do the conversion ( a 205 GTI wiring loom is nothing compared to the 405 T16 loom; see the pictures), but that is going to cost me a ride to the other side of Holland probably since the dealer in my neighborhood isn’t willing to help (apparently there is a difference between service and service. Even when you consider that I spend a fortune on parts there every year). It’s best if I depart early then, cause it seems that there are more then 5 manuals (A4 size, thickness yellow pages) for the wiring alone. I think I have a lot of research to do. But unfortunately……… the story continues.

Hello after more then a few weeks I’m back. During those weeks not much is done on the convertible. I started combining a gearbox for all the T16 force. First I looked at all the possibilities. So I took all the ratios and final drives that are available for Peugeot and along with the formula (see tech. story about gearboxes on this site) and searched for the ideal combination. Preferably a combination with parts of gearboxes I already owned. So I had the choice to use parts from a diesel, 1.6 GTI, 1.6 close ratio and a 1.9 GTI gearbox. Further I could also use a 1.9 MI16 gearbox if that should give better results (Sander thank you for the offer). But that wasn't necessary in the end. I only needed the gears of the 1.8 diesel gearbox and the final drive of the 1.9 GTI. The combination delivered nice long gears that aren’t bad at all for a turbo engine. It keeps pushing anyway when the turbo kicks in. Short gears would only irritate you if you have to shift like a madman all the time. Well the combination was found. What next??

	Yes again that is what I thought. The CTI was still completely stripped and couldn’t be fixed yet (damage) cause the aim-bench I could use wasn’t available for at least one more week. Also I had to find the time to bring the CTI over there during day-time. So what do you do then? Since I was looking at the boxes which contained all my different gearboxes and my gearbox still needed to be made, I took them out of the rack and collected the needed parts.

	There is one thing I really hate and that is a dirty, greasy and smelly gearbox of a 205. Those things are always really dirty cause they are always leaking. That’s why I always walk around with black hands for a few days after working on a gearbox.
	I’m one of the lucky (not!) persons who has rough hands. So even after washing them for the 8^th time with garagesoap I never seem to get my hands completely clean. Disgusting. So now I was already sick of it in advance.
	After a bit of thinking I came up with this idea. Clean the gearbox inside out and paint it black with special paint (engine paint). The results are visible on the pictures. You like it? I do and I don’t get dirty hands now anymore from the gearbox.
	I also replaced all bearings of the gearbox and all the oil-seals. The only thing I’m missing at this moment is a synchromesh from a BE3 gearbox. But I will obtain one of those soon most likely. When I have it I can put the gearbox together again so it can be mounted on the T16 engine.

At this point it was time to arrange some electrical schemes because I didn’t had all the ones I needed. Also I arranged a 205 1.8 diesel for Hilgert (cause he still needed a lot of material for his V6 project. Things like doors, new model dashboard, BE3 gearbox and more). This car will be stripped soon also. It also gives me the opportunity to take a look at the left front of the car to see if it is the same as my CTI. If so I could use the complete left front and place it in my CTI (alright Hilgert?). But we will see if that is possible next week when the diesel arrives. Well I shall stop then cause there isn’t anything left to tell you for now. So I will see you in a while.

Hi at this point a few days have passed and I finally have all the electrical schemes from the 405 T16 that I need. Not only the electrical ones, but also two books specifically for the T16. One describes the injection system completely and the other all the special parts that can be found on a T16 (for instance the gearbox, turbo, drive-line, specifications and more). Acquiring this information was difficult cause most dealers aren’t very willing to help you out, but after a long while searching I found a dealer that was very helpful. Car company and Peugeot dealer “Nivo” in Boxtel Holland once again thank you very much for all your help (You guys can expect me soon when I’m coming to show the 205 CTI). This is one of the few dealers left that has a heart for Peugeot and appreciates the hobby. Okay now we have the schemes what’s next? Well an answer to that isn’t very difficult. Take the wiring loom of the 405 T16 and spread it out over the ground to see what it all contains. Trust me that isn’t easy since not all wire numbers on the cables were intact or there at all. But fortunately the plugs are described as well on the schemes so finding out what the function of every wire is should be possible. Since I wanted to use the 405 wiring loom completely instead of the 205 one ( to make servicing easier) it would be a monster of a job to make the wiring loom suitable for the 205. Wires needed to be removed or shortened to fit the 205. A lot could be removed, because not all is present in a 205 (like electronic differential, 4WD, air-conditioning and more). So I started removing relays and wires from the loom. So give me a few weeks and the loom should be ready.

	The next thing I’m going to do is mounting the engine temporally in the engine bay and take a look at how all cables and parts of the engine must be fitted. That way I could make all hoses the right size/shape and make mounting braces that might be needed. Also making the wiring loom fit in the 205. And taking a look how to fit the radiator. As you can see a lot of plans and work needs to be done and so I will begin working on it now.

The Garrett T25-VAT turbo has a variable turbine passage. This type of turbo was introduced on the 405 T16 in 1991. A movable tongue is mounted in the throat of the turbine housing. This stainless steel tongue is mounted on an axle and is able to maximally rotate 28 degrees. The position of the tongue is regulated by the influence of a pneumatic cylinder controlled by the electronic valve that is controlled by the motor management.

At low revs and/or load there is only a small passage between the movable tongue and the turbine housing. At high revs and/or load the passage gets larger. By doing so the available exhaust gasses always give maximal acceleration. Except for this system this turbo also has a normal waste-gate. This waste-gate also is actuated by a pneumatic cylinder controlled by the electronic valve that is controlled by the motor management. The combination of these two turbo regulations provides an optimal pressure filling. Under certain circumstances an increased turbo pressure can be obtained (1.3 bar instead of 1.1). This over-boost period lasts maximally 45 seconds but can be restarted 1/10 of a second after termination if all the required conditions are still there. These are:

1. Which gear is the car in. A sensor determines the transmission between car speed and engine rev. In 1^st gear or reverse no extra boost is delivered.

2. The temperature of the inlet air after the inter-cooler may not exceed the 80 degrees Celsius.

3. Extra boost is only delivered when the throttle is actuated fully and quickly.

After a long period of hearing nothing from me I’m back. There isn’t much work done in the meanwhile. I went on holiday and had to do a lot of other things after that as well. But time has come and I can make more time to work on my project some more. How are we doing until now?.. Because it wasn’t possible to cut out a piece out of the diesel from Hilgert before it went to the junkyard I had to find another 205. Fortunately a lot of 205s can be found on the junkyard so that didn’t give much problems. So I got myself a piece and started working on it so that it could be placed in the CTI. Now it was time to wait until the owner of the body-shop could find some time to help me. But after a long period of time my car is still standing on the bench. Most likely tommorow it will be ready. Perfectly repaired. Besides that I’ve been quite busy. I ordered a new roof that I could pick up this week. Also some sideskirts were ordered but with them came a delivery period of 4 weeks. That’s what you get when a car model gets a predecessor (the 206). Styling parts (in Holland) are only made on order at that point. Not that the 4 weeks delivery time are a problem, but my appointment with the RDW (import / MOT check) is. In the beginning of October, the 9^th, the car is scheduled to be checked for importing it. It’s always possible to re-schedule the appointment but that isn’t something I want to do. Cause of course getting the car on the road legally as soon as possible is what I want. Especially cause I just sold my blue GTI and won’t be able to drive that car much longer. But getting the CTI painted and put it back together again in a few days just isn’t possible. So I am first going to make the car ready for a paintjob, then the engine-bay will be sprayed and after that the 1.9 GTI engine (temporarily) and the largest part of the interior will be installed. Then the car can be imported. Immediately after that the side skirts can be glued on the car and the interior can be stripped from the car again. Now the complete car is ready for a complete paintjob (the engine bay excluded). Once the car is back from the paint shop I will give you a new update.

Meanwhile a few weeks have past and the inside of the car is completely sprayed. Uh? Yes ….. the CTI was supposed to be ready for the checkup in order to import the car. And well it was completely (and I really mean completely) stripped. Just a bare chassis. So I called the check up point to ask what should be present on a car in order to pass the tests. Luckily the roof and all the side windows didn’t have to be on the car. So I started installing all necessary things. First we removed the 1.9 GTI engine from the GTI of Hilgert (in one piece, complete with subframe, wheels, etc.) and placed it under the CTI. That was the engine. Now the wiring loom was next. And after that the dashboard. After a week working (and about two hours of sleep per day) I was ready. I just in time had the headlights and CO level properly adjusted on the same day as the checkup. If that wasn’t right I had to return for a re-checkup. Almost in the nick of time solved some problems with the clutch cable (putting a BE-1 gearbox on a car that normally has an BE-3 gearbox gives problems). Just 5 minutes before my appointment I arrived at the checkup point. So that’s the moment. You are standing there with your Benneton CTI, which only has some chairs and a dashboard in it. I can tell you that really attracted a lot of attention from all the people present (also customs). Resulting in the fact that your car is inspected a lot more thorough. But on the other hand that is also a very good test to see if the damage is repaired well. But the only thing they found was that the rear brakes were different in brake force and that steering was to heavy (it didn’t came back in center position because of that). Or in other words the damage was repaired extremely well, but I didn’t pass all the tests. I had to come back for a re-checkup for the mentioned points. I was lucky that I could come back within two days. After having replaced the steering housing and cleaning the rear brakes I went back on Wednesday. The result was that within two minutes I was standing outside again and this time the car passed the tests. Well what is keeping me from walking two counters further to customs and bringing some money to the government? Sad but true nowadays we always have to pay 10% BPM regardless the age of the car. The amount of money (BPM) depends not only from the car itself but also its accessories. Fortunately my (bare) car didn’t had any so I could expect the lowest possible amount of BPM for a 205 CTI. That is the only moment when you are glad you don’t have a full-leather interior, powered steering, electrical roof and things like that on your car. That was standing at home waiting for me. Once I got home I found out that not having slept a lot (I never went to bed before 03:30 and had to get up rather early) was getting to me. Even now I’m still recovering.

But despite that together with Chuck and Koen I removed Hilgerts engine from the CTI and swapped a gearbox from another 205. We took our time though. That’s the difference when you don’t have to work against a clock. Tommorow I will finish my own gearbox so that it can be mounted on the T16 engine. After that the T16 engine will be placed in the CTI this week. But I’m hitting the sack for now and going to sleep out. You’ll be hearing from me later.