Peugeot 505 GTI - V6 conversion

[Demannu]

Another day, another bracket.

I wasn't comfortable with the idler pulley between the crankshaft and power steering pump being bolted directly into an aluminium boss on the timing chain cover. So I made a bracket to go between two bosses, spreading the load and eliminating the risk of any flex that might cause a failure of the aluminium.

As a trade off, the pulley is a bit lower, which reduces the wrap around the pulleys, but I think it's a worthy compromise.

I'll let the pictures tell the story!

 

[David S]

That idler was part of the original XM/605 belt tensioner. It's not a very large bearing and I've replaced it more than once on my XM, so I'd be thinking about finding something more robust. Leftover ES9 timing belt idler say?

 

[Demannu]

That idler was part of the original XM/605 belt tensioner. It's not a very large bearing and I've replaced it more than once on my XM, so I'd be thinking about finding something more robust. Leftover ES9 timing belt idler say?

Thanks David, that's good advice. You're absolutely right, that is the original 605 tensioner repurposed. I'll see if it's possible to replace the bearing in it, but I will look at other options.

 

[Demannu]

More brackets! This one is no doubt going to be the most complex though. It incorporates an idler pulley and a tensioner pulley, as well as a method of tensioning.

I didn't take any progress shots, but it's fairly self-explanatory how it all comes together. The tensioner arrangement allows about 60mm 'swing' at the centre of the tensioner pulley, which should give me a fair bit of flexibility with belt lengths.

The more I look at it, the more I think I should cut some holes in it to make it lighter. But then I think if I'm that worried about weight, I should probably just pass on that morning coffee scroll instead.

I'll look at it in daylight before I sandblast and paint it, in case I want to make any more last minute adjustments!

 

[jonhardy]

Nice work Scott.

 

[Demannu]

Apologies for the gap in progress, I've been away for work for a couple of weeks, so it's time to get back into it!

I've made a couple of tweaks to the tensioner arrangement, and I think I'm happy with it now. I've blasted and painted it, and it doesn't look too bad. Belts are on order.

Today I went on a shopping spree to my local bolt place, industrial supplier and exhaust shop.

I bought a longer bolt for the distributor drive, so the threads have the same engagement length as the original camshaft bolt:

And I bought some M7 nuts and bolts to turn into new exhaust studs...

And some mandrel bends to transform into an inlet manifold....

And last night I got out to the shed and started the flanges for the inlet manifold. The first one will bolt to the back of the factory manifold, and the second to the factory throttle body.

Unfortunately my mill is out of commission at the moment, so the workaround is a bit laborious:

Easy bit done, onto the hard bit:

Final result is a bit rough, but the pipes will actually go into this hole, and when welded up will be perfectly neat:

How do you eat an elephant? One bite at a time!

 

[Peter C]

As always, great work, Scott.

 

[alan_505]

Scotty, it must surely be time for an update please!

 

[Adrian Wuillemi]

Scott, might be a good idea to put a lock nut on the tensioner. Stop the bolt backing out with vibrations.

 

[Demannu]

I really wish there was more to tell, but it's been a crazy few weeks! Travelling for work, starting a new job and then for the past week I've been down with the flu. Nonetheless, here is an outline of the few changes that have happened.

Agree with all of those who suggested that the tensioner needs a locking nut - done. Was always part of the plan, just had to find the appropriately flanged nut and non-flanged bolt.

Managed to find a brand new clutch to suit at a reasonable price. Thanks, ebay.

Have cut and tacked up an inlet manifold. Still need to add fittings for vacuum break booster, MAP sensor, inlet temperature sensor and idle speed controller.

Another angle....

How it fits at the back of the engine....

View from the firewall end....

With the throttle body mated up...

And finally the excess material removed from the rear of the rocker cover to tidy it up a bit. On the 605 engine, the material that was here was used to mount the power steering pump.

I've also made all new exhaust studs, chased the threads in the heads with a tap, and fitted the exhaust manifolds.

Just today the belts arrived in the mail for the engine, so I will test them out soon.

Next steps will be to get the engine resealed, properly cleaned and give it a coat of paint to freshen it up, then I'll move onto the wiring and inlet manifold. I feel like those two need to be closely linked, as there is a bit of work to make sure that the wiring is neat but reaches everything essential.

 

[pugrambo]

Couldn't you use a 604 rocker cover instead ?

 

[Demannu]

No, because I wanted to retain the later style air conditioner compressor mounting arrangement. It is simpler, more robust and neater than the earlier options, and keeps the compressor about 30mm further inboard, which gives more clearance between it and the brake master for the air inlet pipe to pass.

 

[Ganesh84]

Sujet très très intéressant !
car moi aussi je me lance dans le même projet, objectif installé un v6 prv 12s provenant d'une Citroën xm sur ma Peugeot 505 gti de 85
je suis content d'être tombé sur le sujet car pas courant et rare comme transformation,
je suis donc à la recherche de toute bonne information, car la liste des modifications est longue !

bien cordialement

 

[COL]

Sujet très très intéressant !
car moi aussi je me lance dans le même projet, objectif installé un v6 prv 12s provenant d'une Citroën xm sur ma Peugeot 505 gti de 85
je suis content d'être tombé sur le sujet car pas courant et rare comme transformation,
je suis donc à la recherche de toute bonne information, car la liste des modifications est longue !

bien cordialement

Very very interesting subject!
because I too am embarking on the same project, objective installed a v6 prv 12s from a Citroën xm on my Peugeot 505 gti from 85
I am happy to have come across the subject because it is not common and rare as a transformation,
so I'm looking for any good information, because the list of changes is long!

Best regards

 

[seasink]

.The sense is: .....the goal being to install a V6......

 

[Demannu]

Hi Ganesh!

Your 505 looks great. Yellow suits it. Please keep us updated with photos as you go!

 

[Demannu]

Today I took a few minutes to check the length of the belt that I ordered. Great result! Tension is perfect with the tensioner at about it's midpoint of travel.

Belt is a 5PK1610. Turns out that it's the same as about 30 years of Saab engines. Dirt cheap, this Dayco belt was $20 delivered.

 

[BP505v6Turbo]

View attachment 243865

Today I took a few minutes to check the length of the belt that I ordered. Great result! Tension is perfect with the tensioner at about it's midpoint of travel.

Belt is a 5PK1610. Turns out that it's the same as about 30 years of Saab engines. Dirt cheap, this Dayco belt was $20 delivered.

Looks good Scotty, I like the power steering on the drivers side good idea, could use Sr sli , gti hoses maybe, will that pump make the steering lighter ?

 

[Ganesh84]

Merci pour votre retour ! Je suis à un stade moins avancé mais je compte bien terminer le projet malgré un grand manque de temps, aujourd'hui je vais déposer à faire sabler la partie inférieure carter / support moteur provenant d'une 504 v6 qui normalement je l'espère doit pouvoir se monter sur le PRV Citroën xm,

 

[Demannu]

Looks good Scotty, I like the power steering on the drivers side good idea, could use Sr sli , gti hoses maybe, will that pump make the steering lighter ?

The 406 pump has the outlet on the side, rather than the back, so I'll have to make up a hose from the original 406 item and the 505 one.
I don't think it will make the steering any lighter, if the pressure is greater I think I can swap the relief valve with the original 505 pump, so performance should be the same.