03/09/2018
Wrote this a while back, but had a few people ask for it on here:
Megane 225/230 Engine Conversion:
First things firstā¦ READ!!!
I do not accept any liability for loss financial or otherwise from completing this conversion, this guide is written in good faith and is to the best of my knowledge correct. Don't cut corners and be safe!!!
If any errors are discovered please contact me.
This guide covers the requirements for replacing the OEM 197 or 200 F4R engine with the Megane 225/230 engine only, and not the Megane gearbox (note the clio gearbox with upratred clutch will run happily with 300lbft and top speed will be140mph), this guide is for a cup ie no air con, but there is no reason why aircon can not be retained it will just be tighter to fit pipework and intercooler etc (personally I would say pull it out).
The car will currently need transporting after fitment of the Megane engine to allow for ecu immobiliser coding, but K-Tec Racing Ltd / RS Tuning Limited are working on a postal service to get the car up and running.
1) Parts Required:
a. Megane 225/230 Complete Engine (all sensors/ancillaries and turbo etc)
b. Megane loom
c. Megane ECU (can have immoboliser code reset, or you would have to ferry the car to the respective tuner).
d. Megane Coolant Hoses
e. Miltek downpipe (decat versions) and front pipe for megane 225 (part Numbers MSRN1199 & MSRN101)
f. Ktec Pro performance system and sports cat (to keep the car MOT legal)
g. Thermal heat insulation sheet for bulkhead approx A4 size sheet should do and RTV to bond
h. Thermal heat wrap for downpipe (15ft of 3ā) and stainless lockwire or snap straps to retain
i. Additional coolant hoses 15mm 10mm for adapting coolant system to suit.
j. Clio 172 Header tank or custom tank would be preferable (I am currently working on a solution that will be available off the shelf from a reputable company).
k. Intercooler pipework (we used a megane 225 hardpiping kit and modified it) and 225 Intercooler (and modified it) setup (ktec are developing conversion intercooler and pipework as I type this and these should be off the shelf items in the future).
l. If modifying a megane hard pipe kit you will need a few odds and sods and a 180degree 51mm bend.
m. Gearbox Oil, Fully Synthetic Oil, Semi-synthetic oil, Coolant, Oil flush, 2x Fiat 1.2 16v 85 approx 1997-1998 oil filters (these are a straight swap and have a much larger filter area)
n. Wd40
o. Lambda b**g
2) Optional Parts
a. Uprated Clio 197 clutch and cover from Helix (the standard system can cope with 330lb/ft but for how long I donāt know ābut no slippage at 1600miles..)
b. NGK Iridium Plugs (BKR7EIX)
c. Meg timing belt kit
To modify intercooler and exhaust you will need TIG welding capability for both aluminium and stainless
Engine Removal
I wonāt cover much detail as if this is to complex donāt try this yourselfā¦
Securely place car on stands, handbrake, chocks etc
Remove battery, battery box, front bumper, arches, slam panel, lights, remove driveshafts from gearbox (after draining oil), aluminium under support/brace, undo exhaust manifold screws, disconnect fuel line (be careful, fire hazard!!!), etc, engine connectors to loom, drain coolant system, remove rad, header tank, etc
With engine hoist you should be able to remove engine and box.
Remove exhaust manifold from car bring it towards the engine bay with jiggling will come out without subframe removal
Prep prior to engine fitting
-Lag down pipe with thermal wrapping
-Use thermal heat insulation sheet behind where fuel lines, body work at back of engine bay will be near to exhaust downpipe and turbo etc (according to VW there should be a minimum air gap of 15mm when fitted āensure no contact and everything is well insulated).
-Drain meg engine of any oil, and replace oil filter.
-Remove gearbox from clio engine
-Replace timing belt now if doing so now
-Use Clio top cam cover/engine mounts for straight fitment.
-Swap over auxiliary belt pulley from clio engine to Meg engine and alternator, brackets etc (if you use the meg pulley you always have a low battery voltage as the alternator will be running slower)
-remove, clutch and flywheel from clio engine and fit to meg (not the bearing on the meg engine crank does not interfere with the clio box and is okay to be left there)
-Fit clio box to meg engine
Engine Fitting
-Fit lagged down pipe, to meg engine
-Fitting engine should now be relatively straight forward.
-With engine fitted driveshafts in box, etc
-Start to refit coolant system, this part requires fabrication, get the majority of Meg pipework in turn the thermostat outlet pipe 180degrees and it will fit straight to the clio rad!
-Get meg coolant pump fitted in position, as it is very tight I used zip ties to position it out of the way of gear linkage etc
-Reassemble bat box then transpose the meg power to the Clio fuse box on the battery box.
The following wiring needs to be carried out:
***Note this involves changing the Meg Loom to match the Clio Body Electronics and not the other way***
Modify the megane loom fitting the clio connectors (from the main fuse box in the engine bay)
note colours don't reflect wire colours just to help show whats going where:
SEE PHOTO COMMENTS FOR WIRING
Also the gearbox pick up for neutral reverse will need to be rewired as the meg box uses two sensors each with two wires and the clio has one but with three wires.
I didnāt note how this should be wired exactly but:
The clio: terminal 2 (yellow) is power, 1 (green) is reverse signal and 3 (violet) is neutral signal
The meg sensor with yellow and white wires, the white is the reverse signal, the yellow is power
This leaves one connection to be made from meg loom to the clio gearbox and this is the neutral signal from the meg box, from memory itās the other sensor lead that isnāt yellow (as yellow is power)
Leave clio ecu in position
Fit header tank, (I trimmed the clio 172 tank down to fit behind the battery) and plumb in this takes a bit of time to get all the fittings and pipe in position.
Fit slam panel and get all intercooler pipework and intercooler in place.
We modified the hard pipe kit from ktec and added in a additional 180degree 51mm alloy bend to get the pipework round the steel leg (front passenger side) that supports the front steel subframe arrangement.
We modified the intercooler, by cutting off the outlet at the back welding a aluminium section over to close up then welded a 51mm straight section on to the end of the intercooler to match up with the pipework.
We fabricated aluminium brackets and welded these to the intercooler and slam panel, holes were drilled to allow screws to hold the intercooler in place
Before tightening all the intercooler and pipework up ensure it is free of debris.
The airfilter is tricky as there is very limited space and I ended up using a pipercross filter as per above with it mounted behind the front bumper for cool air.
Next fit Miltek link pipe and exhaust system, mark sports cat where link pipe comes too and cut and weld the two together so sports cat and link pipe fit in (lambda b**g will be required).
Reconnect battery ensuring all earths are fitted and wiring is complete.
Top up oil (semi synth) and coolant (bleed system best you can), remove coils and plugs and give a healthy spray of wd40 in each bore, allow soaking for 30mins. Turn engine over by hand 2/3turns, respray wd40 and refit plugs (new ones recommended) and coils.
The car should now be ready for K-Tec Racing Ltd / RS Tuning Limited, for immobiliser coding āthe car will need to be transported to them or have them remove the immoboliser code in advance.
Car should be delivered with the bottle of fully synthetic, other new oil filter and the engine flush.
Ask ktec to warm engine up add engine flush, hold at fast idle for 10mins
Remove filter and drop oil, replace with fully synthetic and new filter
Car should now be ready for running properly, keep an eye on coolant as this will no doubt drop
Think thatās everything but proberly notā¦ all in all a lot of work but achievable if you know what your doing.
Big thanks to Jim and Kate JKM Motor Services Ltd / JKM Performance for all their help and allowing me to make a massive mess..
-Andy
