Peugeot 205 Mi16 Build

This Peugeot 205 with an Mi16 swap and ITBs came in with a mix of running and non-start issues. It was running both the original ECU and a piggyback setup, which meant two looms wrapped around everything and a lot of old, spliced and generally tired wiring.

We started by stripping it right back—removing the original ECU, piggyback system and all the wiring—so we could build it back up properly from scratch.

The original distributor and coil setup was also removed and replaced with a wasted spark coilpack to get rid of a common weak point and improve overall reliability.

To mount this, we 3D scanned the side of the head and designed a distributor blanking cap that doubles as a coilpack bracket. There are kits out there for this, but most don’t work if you’re running factory power steering. This setup keeps everything in place without needing to lose that.

We finished off the ignition side with a suitable coilpack and a set of custom HT leads.

The power side of things was also simplified. The original relay setup in the engine bay was removed and replaced with a sealed unit inside the car, now running the ECU, injectors, fuel pump and fans off one clean system.

We also replaced the old fuel lines with biofuel-safe ones as the originals had started to corrode, and fitted a new fuel pressure regulator at the same time.

We did get the car briefly on the dyno and saw ~180bhp, up from the factory 160bhp but had some setup issues at the time of calibrating with the crank sensor. There’s definitely more in it with more time on the map, but it was a solid result for where it’s at and can be improved!