Peugeot 205GTI/Mi16 Conversion Guide/Story
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  1. #1
    Fellow Frogger! neil's Avatar
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    Default Peugeot 205GTI/Mi16 Conversion Guide/Story

    Neilís MI16/205GTI Conversion

    This is for a S1 1987 205gti with a S1 Mi16 engine and gearbox, I will only give a quick guide to the wiring, as to be honest even to today Iím not sure how I managed to get it started.

    I will start with the easy stuff, find a S1 MI16 engine/gearbox. You want the alloy wet sleave block, inlet/exhaust, the full wiring loom, ECU, Mi16 exhaust downpipe and optional gearbox. In my conversion I used the Mi16 gearbox but you can use your 8v box.

    Next I elected to replace a number of things while the engine is out of the car, namely the clutch, water pump and cam belt. These components are not that expensive and it makes sense to do them now. Before the engine goes in you need to make a wedge for the exhaust manifold in order for it to clear the firewall. I used the exhaust manifold gasket and took it to an exhaust shop with a gas cutter to cut the out the shape of 10mil mild steel. The next step is to get milled down on an angle; the top remains at 10mil and milled down to 5mil at the bottom. This puts enough angle on the exhaust manifold to clear the firewall. Refer the photo below. This will cost you about $100 bucks to get done and you will need to use two exhaust manifold gaskets. This completes the prep you need to do before you drop the puppy in.
    <img src="http://home.iprimus.com.au/bwjones/neil/001.jpg" alt=" - " />

    The easiest thing in this conversion is pulling the old 8V out and dropping in the new 16V. To make it easy remove the radiator and all the associated AC gear and fan shrouds. You will need to remove the drive shafts, old wiring loom and ECU. Once all this is out you can get the chance to clean the years of oil and dirt build-up on the firewall, cross member and steering rack. The next thing you will need to do before dropping in the engine is putting a tilt on the brake master cylinder. To do this you need to remove the brake peddle box, to do this you need to unbolt it from inside the car (this is quite time consuming and can frustrate you as you are on you back under the steering wheel). Once you have unbolted it all you can remove it from the engine bay, you should have in your hands the brake peddle, brake booster and the master cylinder. Now you need to put 3-4 washers in between the brake booster and backing plate, this will tilt the master cylinder up and enable it to clear the cambelt cover.
    <img src="http://home.iprimus.com.au/bwjones/neil/002.jpg" alt=" - " />

    You are now ready to drop the donk in. I pulled the old engine out from under the car however I dropped the 16V in via the top. This is easy to do and all the pick-up points are the same (I did replace all the engine mounts before dropping in the new engine). I dropped the engine in without the inlet manifold on, this allows you to do the wiring and gives you more room to swing spanners with the alternator and the water hoses. Iím not going to talk about the wiring as I found this the hardest thing to do and to be honest Iím not sure how I managed to get it started. However the Mi16 ECU and wiring is a stand alone unit and all you need to do is get power to the ECU and to the fuel pump and it should start. All the instruments ie oil temp/pressure, water temp, alternator and starter motor you should just use your existing 8V wiring. This is all I will comment on the wiring side, if you are doing this conversion there are many sites and posts about the wiring should you run into trouble. Now its time to bolt it all back together, the drive shafts should just bolt in, inlet manifold on, alternator, and starter motor.
    <img src="http://home.iprimus.com.au/bwjones/neil/004.jpg" alt=" - " />

    <img src="http://home.iprimus.com.au/bwjones/neil/005.jpg" alt=" - " />
    <img src="http://home.iprimus.com.au/bwjones/neil/006.jpg" alt=" - " />

    You may read on other sites in the UK that you need to shorten the inlet manifold or tilt the engine in order to get it to fit. I wanted to fit the engine without tilting it and without shortening the inlet manifold as it was designed to have this manifold and tilt on the engine. Next you will need to get your trusty angle grinder and attack the fan shroud, you need to grind the shroud so that the radiator is flush with the fans using the lower mount. I have lost the AC as it didnít work before and I will not be using it for an every day car. You can now put the radiator assembly back in, I used a space to tilt the radiator out only by 5mil. This set up will allow you to use the standard manifold and not tilt the engine.
    <img src="http://home.iprimus.com.au/bwjones/neil/008.jpg" alt=" - " />

    All that should be left to do now is fill it with water, oil and turn the Key vrooooom? After I got to this stage I took it to the exhaust shop and fitted a new 2.25 inc system including a new high flow cat. While I was doing the engine conversion I fitted new Koni Yellowís on all four corners, new springs and a set of S2 wheels and sticky rubber. I love the car in its current configuration it is fast in a straight line and even quicker through the corners. For anybody attempting this conversion I would recommend fitting a baffled sump and LSD, which Iím in the process of doing.
    <img src="http://home.iprimus.com.au/bwjones/neil/010.jpg" alt=" - " />
    <img src="http://home.iprimus.com.au/bwjones/neil/011.jpg" alt=" - " />
    The conversion cost approximately $3500 including the engine and it is something you can do yourself. I would like to take this opportunity to thank a number of Froggy members, Adrian, Peter T, Ben(for the donk), Steve, Cal and Brad. Any questions feel free to ask and I will try to help or point you in the right direction as to who can help you.

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    Future modifications will include a Baffled Sump, upgraded front brakes to S2 at least, Cage/race seats and LSD.

    <small>[ 21 October 2003, 08:52 PM: Message edited by: neil 416 ]</small>
    Last edited by gibgib; 25th April 2004 at 09:36 PM. Reason: Title edit only
    205GTI/Mi16
    Tony Sprint Kart

  2. #2
    Fellow Frogger! briz205's Avatar
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    Hi Neil,

    Awesome looking 205 good to see another one on the road. I will have my 205/mi16 shop ready shortly and I want to get a few cars around so if you would mind bring the mi i would be very greatful. If you need any parts new or used give us a bell.

    Nick
    Auckland NZ -
    2000 Peugeot 406 Coupe, Dark Green.
    2001 Renault Clio Sport RS, Silver.

    Brisbane Aus -
    1989 Peugeot 205 GTi, Light Blue.

  3. #3
    Fellow Frogger! WRX2PUG's Avatar
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    Hey Neil, looking good - nice and clean (and fast )

    Did you paint your rocker cover yourself? I had mine painted red as well but was interested in whether you originally masked the Mi16 logo and fins part so it didn't get painted or whether you sanded this back after painting. I'm keen to do this on mine but am worried about the paint flaking if I do..

    Cheers
    Steve
    Renault Clio F1R27 road car and Supercharged Lotus Elise track car

  4. #4
    Fellow Frogger! neil's Avatar
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    Hi Steve

    I painted it myself using heat paint and I put grease on the fins do the paint did not stick.

    Paint is yet to flake
    Neil
    205GTI/Mi16
    Tony Sprint Kart

  5. #5
    Gus
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    Fellow Frogger! Gus's Avatar
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    Nice guide, nice pics... definitely the most-wanted 205 conversion for a reason. . I wanna drive one *grin*.

    Just out of interest... how tight is that fit? It looks _tiiight_. Are there operations (cambelt for starters) which are going to need the engine pulled out first?

  6. #6
    1000+ Posts parry's Avatar
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    How much did the exhaust set you back Neil?
    90 205 Gti Cherry Red(Track Car)
    2009 207gti
    1985 505gti (Shitbox Rally) Sold

    PBs:

    Oran Park: 1:27:9
    Wakefield: 1:05.6 (July 2015)
    Eastern Creek: 1:54 (8v) 1:48 (16V)
    Mt Huntley: 34.44 (2004 stock 205)
    Ringwood: 35.06 (30/10/2005)
    Winton: 1:33.6 (2017)

  7. #7
    Fellow Frogger! neil's Avatar
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    Full exhaust cost $450 including the cat. 2.25inc straight through from the bend in the Mi16 down pipe.

    The wedge cost about $100 from memory. If you have trouble getting it done I can organise one from this end. All I need is an Mi16 exhaust gasket.

    Neil
    205GTI/Mi16
    Tony Sprint Kart

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