Most of the buildlog for my Peugeot 206 CC with EW10J4 engine.
This entire document is in (mostly) chronological order.

The main reason for sharing this is so that other 206 owners can maybe use this information to turn their car into a nice shitbrick.
I am very well aware that none of the things I’m doing to my car make sense from a financial aspect, however, it allows me to try and learn things for later when I want to build a nicer looking, more expensive shitbrick.

Unlooming some plugs

Since my climate control unit died (the fan died and was really stuck into place) and a bunch of other stuff broke, I decided to remove it (this happens later on the page).
In order to prepare it, I decided to already cut a bunch of cables and remove them to clean everything up a bit.
Please, do be more careful than I was, as I spent a good day or so trying to figure out my hazard lights because I cut them off by accident.
Due to the mid-dash also being gone (as that was the part that broke), I also have no radio head-unit and decided to also remove the radio wiring up-to the plug in the fuse-box.

c795a5ed be99 4e4f 8b09 3422dcd41c47
rn image picker lib temp 71a643b2 b17b 4c2e 8101 7453a769e942
f60842e7 ec87 4a1b bce9 d25b63b95bf1
rn image picker lib temp 69ba7fef 8af7 4df0 8bf9 52f8863c844c

The only wires that I kept were those for the hazard lights, which I rewired to the old radio control stick.
As this stick never worked for me (previous owner installed an aftermarket headunit), this felt like a good solution for now.

While this process didn’t give me much performance or anything, it just cleaned up a bit, made everything less likely to short-out and meant I didn’t have to deal with a bunch of cables when I eventually start removing the climate control unit itself.

K&N Airfilter

The airfilter was replaced with a K&N 33-2813.
This didn’t give me any noticeable performance but I got it on sale for just 2 euro more than an OEM paper air-filter, so it’s not too bad.
And maybe it’ll give me some extra performance after mapping it later, who knows.

Interior stripping

Because the interior weighs quite a lot but doesn’t do much for me personally, I’ve opted to remove most of it.
Additionally, this had the benefit of showing me some rust spots I wouldn’t have found otherwise.

Sadly, I do not have pictures of removal of a lot of stuff so you’ll have to find this one out for yourself.
If you just gently pull at stuff, it should tell you where it’s being held in by more screws or bolts.
As for the removal of the carpets and a bunch of the insulation, I just carefully used a boxcutter to remove them.

IMG 20230714 161025
rn image picker lib temp 2cf0fc62 3d91 4b59 9a98 697ffce91e1b
IMG 20230718 122100
IMG 20230914 192232
IMG 20230914 192221

For the "door handles", I just used some OMP tow straps.
I’ll cover the doors in either some "cartonfibre", polycarbonate or something else at a later date.

55e1c568 5e66 438e a9ed 4667e04ec428

ECU Replacement

In order to minimize risk of running into issues later, I opted to replace my ECU prematurely.
As I did not want to have to deal with re-doing any wiring harnesses for the engine, my only two options were the Megasquirt MS3 PNP from Pirata Motor and the VEMS PNP from DP Engineering.

Due to having limited experience with engine mapping and some weird things outlined on the site of the MS3 (such as CLT sensor not working as normal), I decided to go with the VEMS system.
That way, I at least had someone relatively local to turn to for help if need be.

For the options I chose:

  • OEM MAP sensor.

  • EGT upgrade without sensor (the sensor will be added at a later date).

  • With knock upgrade.

  • With wideband functionality and pre-calibrated Bosch LSU 4.9 sensor.

  • OEM air temperature sensor.

  • No internal memory card (I might add this myself at a later date).

  • No Bluetooth transmitter (I hate bluetooth).

Installation, however, required me to remove the original bracket and zip-tie the thing to some other bracket instead.
While this is not ideal, I’ll fix it at a later date…​ Maybe…​

rn image picker lib temp 6049ebbc 1b26 4d91 bc4d f756a6ecb9ca

Engine base map

After playing with the VEMS for a while doing some road-tuning, I decided to bring it to DP Engineering.
Since my setup at this time is really easy to reproduce if you buy a stock EW10J4 car, you can download my VEMS config here.
It should work with any stock EW10J4, though it may require very minor tweaks here and there.

Sadly, DP-Engineering could only get 132hp out of the engine, this is probably due to wear on the block.
I might have the engine rebuilt someday but it’s fairly unlikely I will.

Update: 16 November, 2023

While doing some data logging, I noticed that my speed read out double what it should be and the gears shown were also incorrect as a result.
Luckily, this was an easy fix as I just had to go to InputsSpeed Sensor and set the Speed sensor divider on the First Speed Sensor to 2.

photo 5958291989986394047 x

It might be that I need to change the Speed sensor trigger edge but I have not yet tested it.
According to the VEMS documentation, this should be set to Rising for most cars, however, the way I’ve done it works just fine for now but I’ll experiment with it later.

TODO: Upload new VEMS Config.

Custom PCV breather Hose

While working on the car, I accidentally broke the PCV breather hose.
This is due to the plastic having become brittle over the 22 years this car has been on the road and me trying to bend it away slightly.
As a new PCV hose would cost nearly €50, I decided to instead take the plastic off the old plugs and make my own.

rn image picker lib temp 0fdbaa62 9e01 46ba 85d0 4ccc486138a1
rn image picker lib temp 411d8a28 d77c 4b9e af0a 36a2e1d67de8
rn image picker lib temp 9e7a50a8 3336 45a1 9c2a 9551494d3387
rn image picker lib temp 5e89facf b8bc 4cdf bf09 259bf91aaa1f

After I had freed the plugs, I needed to get the hosing to put it all together again.
So first, I needed to figure out the outer-diameter of the plugs (which will be the inner-diameter of the hosing).
After some measuring, this is what I got:

  • T-split: 13mm + 7mm

  • Engine: 12mm

  • Before-tb: 12mm

  • After-tb: 7mm

I then ordered some simple transparent silicone vacuum hosing.
Since there was no 7mm hosing, I instead opted for 6mm hosing.
I could have gone for some nice looking blue hosing instead but this would have doubled the price.
In the end, this costed me about 21 euro including shipping.

About 5 minutes of measuring and cutting later, we have a new PCV breather hose.

IMG 20231025 173111

EGR blanking

Since the VEMS doesn’t control the EGR, the valve could be removed from the car.
The original valve is quite a hefty thing coming in at about a kilogram (guesstimate, not actually weighted) so this also saved some weight.
I ordered the valve from a Polish company called Tafmet since I do not have the means of making one myself.

On Tafmet’s website, they show it that you need to place it between the original EGR valve and the engine block, however, I found that using 2 shorter bolts (I do not know the diameter nor thread pitch out of my head) and leaving the EGR off completely worked like a charm.
I just need to find out what to do with the leftover wiring connector but that’s a problem for future me.

photo 5951970463846612930 y

WIP: Exhaust Manifold Replacement

I decided to upgrade the Exhaust Manifold to hopefully remove some restrictions, as well as increase scavenging a bit.
Instead of going for something fancy and custom, I decided to just go with the manifold of the 206 RC instead.

Future: Climate Control Unit Removal

Future: New heater system

Future: Fixing window leaks

Future: Wheels + Tires

Future: Suspension

Future: Seat replacement

Future: Rollcage