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 Posted: Tue May 19, 2020 6:06 pm |
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Joined: Jan 06, 2020
Posts: 176
Trade Rating: 0
Location: Cheshire
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I'm crap at getting photos but SWMBO has probably got a few pics of this latest project car. Bought last week as a non-runner with MoT till September, this Obsidian Black '03 206 was a fairly low spec 1.1 S with 94k on the clock and a tidy body as well as some BSA alloys with 4 new tyres.
Within the hour of it being delivered, we had it running sweetly (well, they don't tend to run very well with a missing BSM now, do they!?! Seriously, that was the only issue...) and took it on a quick jaunt around to confirm it drove as good as it looked, which it does. Then by the end of day 2 the "face" was removed and engine/box was out and on the garage floor (will possibly list for sale here shortly).
We've got our engine as a basis to fit, out of an early Xantia, and have given it a quick test-fire on the crane this afternoon. Turbo was blowing a little oil & the fuel pump might need swapping to a spare one as it wasn't pulling fuel from the can on it's own but the basis seems healthy enough.
Plan is, once we have a suitable gearbox etc, is to make a steel tubular exhaust manifold to bring the turbo mounting round to above the gearbox (for both space constraint reasons and for accessibility for changing setups). Will probably have to relocate the battery and BSM although might get away with that. Intake will be behind the headlamp, front mount intercooler in front of the rad etc. Will ask Emma to email any pics she has to me & get them up here later.
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| '02 1.4HDi Mercury Grey 102k (waiting for it's time to shine once more)
'03 GTi 180 Aegean Blue 92k (suffering gearbox/diff issues)
'53 Obsidian Black XUD9TE/veg fuelled b-road toy (in surgery for MoT workarounds)
'56 SW 1.4i Verve Aegean Blue 70k (new £50 project with roasted lump)
+'95 Citroen Xantia 1.9D auto (on loan to inlaws)
+'99 306 2.0SE cabriolet
+'97 306 1.9LXDT
French Car Forums | |
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Posted: Wed May 20, 2020 8:33 pm |
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Joined: Jan 06, 2020
Posts: 176
Trade Rating: 0
Location: Cheshire
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Little bit of an update on this, we might have a gearbox. Found a complete 2.0 HDi lump and 'box from a 406 for £30 locally. If that deal comes off then progress can be made. Was hoping to keep a cable clutch for simplicity but for the price I don't mind going hydro...
Got a few photos the better half took, and a video of the engine startup I'll stick on YT as can't upload it here...
On it's way to a new home... All innocent and petrol-y 
"Non-runner" out for a nice drive & photo op
I'm an engine, me...
The real new engine!
The neighbours love me & my smokey old starts...
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| '02 1.4HDi Mercury Grey 102k (waiting for it's time to shine once more)
'03 GTi 180 Aegean Blue 92k (suffering gearbox/diff issues)
'53 Obsidian Black XUD9TE/veg fuelled b-road toy (in surgery for MoT workarounds)
'56 SW 1.4i Verve Aegean Blue 70k (new £50 project with roasted lump)
+'95 Citroen Xantia 1.9D auto (on loan to inlaws)
+'99 306 2.0SE cabriolet
+'97 306 1.9LXDT
French Car Forums | |
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Posted: Thu May 21, 2020 4:31 pm |
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Joined: Jan 06, 2020
Posts: 176
Trade Rating: 0
Location: Cheshire
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406 HDi Gearbox and engine collected and home now 
Means I'll have to play with driveshafts, clutch setup and shift linkages but don't mind that for the price! Anyone else gone to cable shift on their 206?
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| '02 1.4HDi Mercury Grey 102k (waiting for it's time to shine once more)
'03 GTi 180 Aegean Blue 92k (suffering gearbox/diff issues)
'53 Obsidian Black XUD9TE/veg fuelled b-road toy (in surgery for MoT workarounds)
'56 SW 1.4i Verve Aegean Blue 70k (new £50 project with roasted lump)
+'95 Citroen Xantia 1.9D auto (on loan to inlaws)
+'99 306 2.0SE cabriolet
+'97 306 1.9LXDT
French Car Forums | |
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Posted: Fri May 22, 2020 5:02 pm |
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Joined: Jan 06, 2020
Posts: 176
Trade Rating: 0
Location: Cheshire
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Fitted the 406 'box to the XUD & had a dry run lifting it into the 206 bay this afternoon. Really need to get a DW8 top engine mount sorted before I can go much further with the fitting as the other 2 mounts will need modifying so at least want that one point of reference. (I might borrow the top mount from our Xantia as a pattern and knock something temporary up out of flat stock/angle iron for now though as i'm impatient! If that turns out well enough might even make a proper one out of steel.)
On the clutch side of things, I've not had a proper look/measure yet but I have a sneaking suspicion that I could make the 1.1's push type release fork & cable arm work in the 406 bellhousing. (need the bellhousing for front starter location of the XUD.)
Also remembered I might have a new CHRA that'd fit the original turbo on the XUD lump, if that's the case then I may skip the fabricated manifold & gearbox mount turbo idea for the moment since then could get up and running a bit quicker & could be fairly confident in running that turbo balls to the wall for a few months before it gets tired & enjoy the car/identify any issues while sorting out making the replacement manifold & pipework.
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| '02 1.4HDi Mercury Grey 102k (waiting for it's time to shine once more)
'03 GTi 180 Aegean Blue 92k (suffering gearbox/diff issues)
'53 Obsidian Black XUD9TE/veg fuelled b-road toy (in surgery for MoT workarounds)
'56 SW 1.4i Verve Aegean Blue 70k (new £50 project with roasted lump)
+'95 Citroen Xantia 1.9D auto (on loan to inlaws)
+'99 306 2.0SE cabriolet
+'97 306 1.9LXDT
French Car Forums | |
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Posted: Sat May 23, 2020 2:06 pm |
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Joined: Jan 06, 2020
Posts: 176
Trade Rating: 0
Location: Cheshire
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SCORE! Just picked up a pretty shabby, down at heel, mega mileage pre-plex'd GTi to donate some bits to the project.
£300 and it's got 180 wheels shod with 4 brand new Uniroyal's, SP grilles/door handles/vents, reasonable interior, coilovers, lowered rear beam not to mention it'll likely provide a nice brake upgrade over the 1.1, give us some hubs suited to larger driveshafts (maybe even the shafts themselves), spoiler and God knows what else.
Seems a shame to break up an early GTi, but it really is quite tatty, has a dinged up shell with some rust in it & just generally ready for a rest. There may or may not be HG issues with the engine too so don't feel too awful about it, and it'll make the TD project a heck of a lot easier. Photos to come when the better half sends them to me. 
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| '02 1.4HDi Mercury Grey 102k (waiting for it's time to shine once more)
'03 GTi 180 Aegean Blue 92k (suffering gearbox/diff issues)
'53 Obsidian Black XUD9TE/veg fuelled b-road toy (in surgery for MoT workarounds)
'56 SW 1.4i Verve Aegean Blue 70k (new £50 project with roasted lump)
+'95 Citroen Xantia 1.9D auto (on loan to inlaws)
+'99 306 2.0SE cabriolet
+'97 306 1.9LXDT
French Car Forums | |
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Posted: Sat May 23, 2020 4:42 pm |
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Joined: Jan 06, 2020
Posts: 176
Trade Rating: 0
Location: Cheshire
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Photo of the donor car, lots and lots of goodies. There was only a brand new bloody WRC spoiler included, sat in the boot still wrapped up and unpainted! What a winner!
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| '02 1.4HDi Mercury Grey 102k (waiting for it's time to shine once more)
'03 GTi 180 Aegean Blue 92k (suffering gearbox/diff issues)
'53 Obsidian Black XUD9TE/veg fuelled b-road toy (in surgery for MoT workarounds)
'56 SW 1.4i Verve Aegean Blue 70k (new £50 project with roasted lump)
+'95 Citroen Xantia 1.9D auto (on loan to inlaws)
+'99 306 2.0SE cabriolet
+'97 306 1.9LXDT
French Car Forums | |
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Posted: Mon May 25, 2020 5:38 pm |
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Joined: Jan 06, 2020
Posts: 176
Trade Rating: 0
Location: Cheshire
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Not a huge amount of progress last couple of days, waiting on a VE pump seal kit, cambelt & manifold gaskets etc to arrive so just stripped ancillaries/fittings off the engine, blocked up the holes & given it all a good clean up to get rid of 28 years of greasy dusty goop and rusty crap. Will give the block/sump a squirt of satin black when it's all cleaned up to make it look tidy & deciding whether to give the cam cover a polish or paint. I like the idea of a polished cam cover & intake plenum in a black car...
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| '02 1.4HDi Mercury Grey 102k (waiting for it's time to shine once more)
'03 GTi 180 Aegean Blue 92k (suffering gearbox/diff issues)
'53 Obsidian Black XUD9TE/veg fuelled b-road toy (in surgery for MoT workarounds)
'56 SW 1.4i Verve Aegean Blue 70k (new £50 project with roasted lump)
+'95 Citroen Xantia 1.9D auto (on loan to inlaws)
+'99 306 2.0SE cabriolet
+'97 306 1.9LXDT
French Car Forums | |
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Posted: Fri May 29, 2020 6:01 pm |
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Joined: Jan 06, 2020
Posts: 176
Trade Rating: 0
Location: Cheshire
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God I'm bad at getting photos! TD engine is loosely sat in the bay currently, on it's second dry-run & lined up pretty decently. Today was mainly beginning to strip the parts GTi though. Gearbox/driveshafts/front suspension/brakes/hydraulic clutch setup/Sport wings & bumper etc all off.
Not an awful lot left that we want just the seats/door cards, driver's door & rear beam to get removed then the shell can wend it's merry way to pug heaven.
Pretty sure the engine does have HG issues as there was plenty of mayonnaise in the top of the radiator, and externally it's drenched in it's own oil from virtually every gasket and seal going. basically what you'd expect from a 175k+ hot hatch engine... Not sure what to do with that yet, it'll either go with the shell or I'll offload it on someone who needs a good core to rebuild!
Seal kit for the pump & the new cambelt have arrived for the TD lump & it'll soon be time for things to start going back together. The fun bit!
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| '02 1.4HDi Mercury Grey 102k (waiting for it's time to shine once more)
'03 GTi 180 Aegean Blue 92k (suffering gearbox/diff issues)
'53 Obsidian Black XUD9TE/veg fuelled b-road toy (in surgery for MoT workarounds)
'56 SW 1.4i Verve Aegean Blue 70k (new £50 project with roasted lump)
+'95 Citroen Xantia 1.9D auto (on loan to inlaws)
+'99 306 2.0SE cabriolet
+'97 306 1.9LXDT
French Car Forums | |
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Posted: Mon Jun 01, 2020 10:06 pm |
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Joined: Jan 06, 2020
Posts: 176
Trade Rating: 0
Location: Cheshire
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Ugh still not got more piccies, but the GTi is stripped and ready for the chains through it. Rear beams come off so nicely when they've not been on there 20 years, and the bolts must have been replaced too as they're like new.
Have located an inlet manifold for the TD along with a set of recon 130bar injectors that'll do nicely for the Xantia, £35ish delivered for that little lot from an understanding fella with a 200bhp 306-engined 405
Got to give scrap man a ring tomorrow, get space freed up on the fronts & then move onto some nice building-things up kinda work. Want to test-fire the engine again and see what the state of play with the original turbo is, since if it's alive then It'll be quicker to get the car running on that with the boost whacked up & I can work out the replacement and it's manifold & mounting etc while enjoying the car a bit.
Also now will have to swap the GTi coilovers/hubs/brakes/180 wheels onto it, probably leave it's ass in the air for the first test runs but going to discs all round is a must really. Struggling to contain my excitement now, got almost everything needed to get the thing running.
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| '02 1.4HDi Mercury Grey 102k (waiting for it's time to shine once more)
'03 GTi 180 Aegean Blue 92k (suffering gearbox/diff issues)
'53 Obsidian Black XUD9TE/veg fuelled b-road toy (in surgery for MoT workarounds)
'56 SW 1.4i Verve Aegean Blue 70k (new £50 project with roasted lump)
+'95 Citroen Xantia 1.9D auto (on loan to inlaws)
+'99 306 2.0SE cabriolet
+'97 306 1.9LXDT
French Car Forums | |
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Posted: Wed Jun 03, 2020 5:49 pm |
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Joined: Dec 26, 2013
Posts: 326
Trade Rating: +1
Location: East London
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Love this thread, keep the updates coming please!
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| Current: Albi Blue Clio 197
Previous: EZR 1.1 206 Zest 3 5dr | |
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Posted: Wed Jun 03, 2020 9:32 pm |
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Joined: Jan 06, 2020
Posts: 176
Trade Rating: 0
Location: Cheshire
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Thanks, really must get round to putting some more photos up but I never think to get pics when I'm busy playing!
Got the GTi gearbox on the diesel lump now, reassembled some ancillaries & fitted the new cambelt and a spare VE pump I had, then bled it out and did another test-fire hoping to assess the turbo since it was very oily when we got it. Sadly though ran into the exact same symptom as before, that being it'd start fairly readily but rev to about 2500rpm and die out after a couple of seconds with no control via the accelerator lever. In fact, just like as if it'd been given a does of easy start.
I had thought this was down to the original pump being knackered/damaged but it seems more likely now it's dribbly/leaky injectors. Will have to pull the injectors back out and look for a spare set of 175 bar injectors I should have lying about, found my used 130bar set no worries. Bloody typical! haha.
We'll get there in the end though, and with ahh, 15k in overnight parts from France, it'll decimate all... 
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| '02 1.4HDi Mercury Grey 102k (waiting for it's time to shine once more)
'03 GTi 180 Aegean Blue 92k (suffering gearbox/diff issues)
'53 Obsidian Black XUD9TE/veg fuelled b-road toy (in surgery for MoT workarounds)
'56 SW 1.4i Verve Aegean Blue 70k (new £50 project with roasted lump)
+'95 Citroen Xantia 1.9D auto (on loan to inlaws)
+'99 306 2.0SE cabriolet
+'97 306 1.9LXDT
French Car Forums | |
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Posted: Sat Jun 06, 2020 3:58 pm |
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Joined: Jun 20, 2012
Posts: 1171
Trade Rating: +1
Location: West Country
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Following this one:)
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Posted: Sat Jun 06, 2020 8:09 pm |
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Joined: Jan 06, 2020
Posts: 176
Trade Rating: 0
Location: Cheshire
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Not done much the last few days as the weather's been pants, starting to wish I'd kept the GTi flywheel as it'd likely be a bit lighter than the XUD and I could've used the spanking new GTi clutch setup. (the disc fouls the flywheel bolts, yes it was the right way round lol). Still, hindsight and all that, pretty sure we'll be staying with the GTi 'box now so that leaves the 2.0HDi setup complete for potential future project/nick the rods out of it if we go nuts with the XUD.
Hopefully the 406 intake and a set of injectors will land Monday/Tuesday & the weather bucks it's ideas up then we can crack on with getting the suspension swapped over & all that good stuff (and get some bloody photos ahaha)
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| '02 1.4HDi Mercury Grey 102k (waiting for it's time to shine once more)
'03 GTi 180 Aegean Blue 92k (suffering gearbox/diff issues)
'53 Obsidian Black XUD9TE/veg fuelled b-road toy (in surgery for MoT workarounds)
'56 SW 1.4i Verve Aegean Blue 70k (new £50 project with roasted lump)
+'95 Citroen Xantia 1.9D auto (on loan to inlaws)
+'99 306 2.0SE cabriolet
+'97 306 1.9LXDT
French Car Forums | |
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Posted: Mon Jun 08, 2020 6:39 pm |
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Joined: May 03, 2020
Posts: 16
Trade Rating: 0
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Nice little project this one! Bargain with the early GTi too! Wish I could find some bargains like that down here!
Keep up the good work brotha
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| 2003 1.4 hdi daily runabout s**t box | |
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Posted: Thu Jun 11, 2020 10:15 pm |
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Joined: Jan 06, 2020
Posts: 176
Trade Rating: 0
Location: Cheshire
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Only a small update thus far, weather's been s**te and had other stuff to do but have stripped down one of the injector pumps to rebuild and mod. What a gummy mess inside, no wonder it wasn't pumping properly. Most of the bits are cleaned now, just left the pump body/flyweights etc soaking overnight to get them minty and clean, should work a lot better with the vanes and timing mechanism not glued in place!!!
Also grabbed a couple of photos finally, not much just some pump gubbins and a half-mounted engine/GTi 'box but that's where we're at for the moment. Engine should fire up and run beautifully with the pump all sorted out though & can get the gov mod and seals done while it's apart.
Not planning an 11mm pump just yet, so this dizzy head needs moar kleen!
Bathtime for Herr Bosch, just don't tell SWMBO that's her jug full of petrol/white spirit!!!
XUD9TE mated to GTi gearbox
See, it really is in a 206... (well, most of one)
Pile of random GTi/GTi180/Xantia TD and 406 HDi parts all waiting their turn to be grafted into the Frankenpug
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| '02 1.4HDi Mercury Grey 102k (waiting for it's time to shine once more)
'03 GTi 180 Aegean Blue 92k (suffering gearbox/diff issues)
'53 Obsidian Black XUD9TE/veg fuelled b-road toy (in surgery for MoT workarounds)
'56 SW 1.4i Verve Aegean Blue 70k (new £50 project with roasted lump)
+'95 Citroen Xantia 1.9D auto (on loan to inlaws)
+'99 306 2.0SE cabriolet
+'97 306 1.9LXDT
French Car Forums | |
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