the picture was crap and it looked dirty, the map sensor was also missing! no roblem!
So their i am, garage all to myself so i set to work removing the ASAC sorry "AVAC" system.. first off comes the plastic runners, easy peasy seeing astho they have been on and off no less than 3 times since ownership!
But next came the ally inlet with 8 bolts, 4 of which being about 7.5" long with a 6mm allenkey head (which all rounded off instantly) so out came the hacksaw.. and after some serious blood sweat and f-words and a good tugg
it came off, (writing this was alot easyer than doing it, it actually took nearly 3 hours)..so next i jetwashed the inlet fannymould and cleaned the throttle body, i didnt go to town and paint it as the rest of the bay is a mess.
i then cleaned the mateing serfaces with a stanley knife blade and went to my local peugeot dealer -(horderns chappel-en-le-frith who are the masters and what all pug dealers should be like!) and bought the inlet to head gasket and tb gasket which they had in stock and cost a bargain £3.42
to fit the manifold i had to reroute the oil filler closer to the slam pannel using some old 205gti water hose i had lying about, its not brilliant but shouldnt be a problem till i next change the oil as the neck isnt sloped as much as it used to be..
next problem was the metal power steering pump pipe which runs across the front of the engine, it foweled the manifold so i carefully bent it away from the manifold so it now runs across the top of the pump rather than between the pump and manifold and closer to the slam pannel.
i then bolted the manifold in place and tb on, i used the standard injectors and fuel rail.
next was the idle control valve- i gutted out the gti 6 icv instead of making up take off plate and mounted the mi16 icv to that using 20mm hose, i used a oil breater filter instead of plumming it back into the airbox because im nut using the oe filter. then a simple bracket was made to mount the icv.
the map sensor hole was blocked off with an ally plate bolted and siliconed into place
i then bloxcked off the top breater on the tb and the bottom one is joined to the charcoal canister (i think.... i hope.. i dunno why...) and the grey ang yellow pugs where plugged in (same as mi16). then took a t-piece off the fuel regulator to go to the vacume on the ecu (thin black pipe).
the throttle body sat so close to the battery i decided to move the battery to the boot, this gave me alot more room so i have now ordered a silicone hose and filter which will sit at the back of the headlight, the iggnition modules where taken off the battery tray and mounted to the inner wing.
and i think thats it..
I took her out for a spin yesterday and oh my god what a difference! first thing you notice is the sound! alot deeper and gti-6ish! then the lack of midrange flat spot WOOOOOHOOOOOOO!!!!!!!!! the only bad thing i noticed was if you set off it struggles abit if you open the throttle to fast im guessing it drowns the engine abit because of the larger tb?!?
Alltogether im really chuffed with the conversion and would highly recomend it!
