#1: Extracting Power from the Tiny HDi Author: southwestchap, Location: DevonPosted: Thu Jul 19, 2012 5:37 am ---- Well, been reading quite a few of the project cars threads that everyone has thought I would like to get in on some of the action too...
...and so it began...
This is how my car came to me in July 2008...
It was a 1.4HDi, 2002 LX, 103k Miles 5 Door, CAT D although I wasn’t too fussed as the damage was only to the bumper re-enforcer mounting bolts (they were bent out of alignment) and a small dink in the passenger side wheel arch. It started and drove fine though it did whine when you revved it however the damage was to be sorted before I could test drive it. So sorted that and picked up (from a scrappy) a standard front bumper, some frosted headlights, slam panel/fan housing and a radiator for £70. Alas no grill. I was going to have to make do with the bonnet being straightened as I couldn’t find one at the breakers.
So bolted it all together and got some number plates on it and it squared up ok apart from the missing front grill and crease in the bonnet. Couple days before it was going in to be MOT’d it had a slight issue with the rear brakes.
Typical Peugeot....the liners had let go from the shoes, so ordered up a set of replacements. Just for good measure I had the front wheels off and greased up the fronts to give the car’s brakes an ‘overhaul’.
The whining was still on-going so I removed the auxiliary belt and fire it up. The whining had gone and I could hear the turbo whistle. So the old man gave me a hand to get the idler pulleys off (I don’t have aircon so I didn’t need to worry about that).
Once they were off in our hands they were a lil rough but had no play in them so we picked the seals out on the bench and filled them with oil but seals back in and replaced on the car. To this day now the car does not whine :).
I made another trip to another scrap yard and immediately spied a set of sport bumpers. So I enquired about price...£30! Due to the front one not having the bump strip. Thought it was cheap enough and in the right colour ish...(Slightly lighter if you concentrate on it) and also found a grill but unfortunately in cherry red....so out with a can of paint and gave it a quick few coats.
Because I wanted the car on the road I just put the grill on to make it complete. Got it MOT’d (passed with flying colours) and I was on the road....after I got my tax of course...
The sports bumper was fitted and I made up some front arch liners to fit, not brilliant but they did the job. The black bump strip was just taken from my standard bumper so that also didn’t fit quite right but I was unable to find the proper sport one. (I was too keen to fit the sports bumper…I know). The honeycomb grill was a little tatty but it would do for now. The rear bumper fitted fine and I come across a pair of rear arch liners for £5 to complete that perfectly.
This is how it then looked. Fogs didn’t work but I read that it needs to be activated in the BSI...done that and get the light on the dash but still no lights...possibly something to do with the wrong fuse box?
Thought I better give it a bit of a service due to not having one for the last 20k (according to the service book) so a new oil, air and pollen filter and some Castrol Edge Turbo Diesel Oil and the car was purring....I’ve read that fuel filters on these don’t need to be changed for 40k....so I’ve left that for another day.
Then it snowed…quite heavily
Found a pair of mudflaps hanging around in the shed and added those.
Went on a bit of a road trip up to a friend’s in Kent...600 mile round trip from Devon! 1 Tank of fuel I was very pleased how it drove up and back. I acquired a basic Kenwood radio and thought to use the AUX Out with my iPod as it wasn’t an MP3 radio. Not a fan of cables running everywhere, like it all tucked in out the way but a bit limited with this radio, so lashed this up on the trip.
My left arm was a bit lost while driving so when I got back it fabricated up (with the help from the old man...his welding skills a far superior than mine) an armrest. I found the actual arm from a transit....colour was blue but not the same as the interior of the 206...oh well I could live with it...bolted it into a hole on the base of the driver’s seat and used the recliner rod as a stabiliser. Bit of a radge but it works rather well.
Shame about that bonnet...though speaking of which...I spied a brand new one on eBay about 20 miles from me...so I had to have that £30...and got it sprayed up read to go on the car. Don’t know why it was jacked up…probably doing something else.
You’ll notice that the front bumper is back to standard. Well was in town one night literally parked up for two minutes and had someone back into me. Nothing too bad, but push the grill of its clips and cracked it. So I thought I would change it back due to a) not having the right bump strip b) not having the right arch liners and c) the grill now worse off.
Drove around fine for a while and ended up with the famous Peugeot knocking from the front. So new set of drop links on the car and we were away again. The old man actually gave these to me as he was going to fit them to his 206.
Both of mine were knackered, bottom joint one side and top joint the other. So he was fairly keen and made one good one out the two. Complete lash up I know but he only needed one.
I liked the fact of the standard radio worked with the stalk and didn’t look too appealing to passersby but the lack of MP3 compatibility was changing my mind...but I come across the Connects2 iPod adaption box of tricks and added that into the equation...I recommend one if you want to keep OEM...
Another problem I had was the com2000 unit suffered the indicator stalk wobble...so bad as it got very annoying so I sourced another unit (from a user on here - forgot the name now but thanks very much ) and fitted that up...it also had the front fog light function so I thought it’ll be ok for my front fog bumper when I get it fitted.
Found a set of crystals on the bay little bit scruffy but they were to be fitted...with the help of Northantsben for his wiring diagrams I had them fitted with the dipped beam staying on with the main beam...
Changed the front speakers to some FLI Integrator 6.5”, they worked well for a time then sold them as I fitted some Fusion Component speakers complete with crossovers. Did amp them but I found it was too much hassle so I discarded these and went and fitted some FLI Underground 6.5” speakers and these have been left in to this day.
Then got a right bargain at a farm sale set of Nimrods well the 14” version. (Not sure what you call them). Good tyres to. Was expecting a £40-50 buy instead…£12 due to being the last lot of the day and hardly anyone was left. You may see that my mirror cap is missing…the hedge claimed this
Went with some friends to a scrap yard down in the depths of Cornwall and found an Sport SP Grill, Gear knob (not SP but better than the bog standard one), SP Fuel cap and a passenger side sports arch liner. The grill had a small amount of damage to it where the GTI had had a front end collision. Did also see some SP pedals down there to but they didn’t seem to want to come off easily (admittedly I didn’t have to right tools for the job) wish I tried harder now! Anyways went and paid for the grill, gear knob, inner arch and cap...£20
Finally I had mostly got everything I needed to fit the front bumper: sports bump strip (found on eBay), SP Grill and had a single passenger side GTI front arch liner...I thought I’d make/adapt something up for the driver’s side as I just wanted to get the bumper fitted properly. Also a tidier set of crystal headlights as mine were not so good.
Had a bit of a fail and had some woman drive in the back of me with a 4x4 Hilux. Unfortunately no pictures stupid phone broke before I had chance to get them off. Luckily it was higher up and only required a boot lid (cracked glass and bit dented). So went to the breakers again and they had a grey tailgate with a spoiler fitted. So took the lot, got it sprayed and swapped it over. Charged the woman for replacement part and paint and hassle to change it all over and I still had some change left over. Not all bad just hassle.
Then it started to get cold again…and the car got dirtier…
Thing I put some chunky (ish) tyres on due to the steelies being back on.
The car has never given up on me since I had it, never actually even seen the engine management light come on so was REALLY surprised to see it light up and beep at me one day I was driving to work. Driving up the dual carriageway during the big freeze and it lit up, however the car was still driving, gauges were normal so I kept going (as I was only 10 miles from work) and limped on.
Upon tuning onto the short stretch of the motorway, I put my foot down to pull up the slip road, the car just died. So across to the hard shoulder and was quite worried though the car fired up again. So drove on steady keeping around 45/50mph. When pulling up the drive to work I put my foot down and it just cut out but restarted and ticked over fine. Lad at work fetched his code reader at lunch but it wouldn’t detect the car.
So I drove home again just steady and had to take it into a local garage with off the electronic toys the next day. Plugged in and had low rail pressure. Cleared it and beat it up the road and it drove fine. We put it down to the shear temperature as it was -6 or something silly.
Car needed a good wash after the wet weather.
Found a set of 205 15” Speedlines. Put them on for a laugh. Caps missing sadly but I did source some in the end.
Tried really hard with the Cruise control, read the whole thread on here for, found a stalk and activated it all in the BSI. The car recognised it all but it didn’t have the light on the dash or the four wires on the brake plug. So sold the stalk and abandoned that, such a shame though as cruise control would be immense.
Sold the speedlines, so back on steelies and plastic.
Was up at a friend’s farm and took a few pictures of the car in the shed. (I know the car isn’t clean... and the wheels aren’t helping)
Fitted a PPT30, so got the use of the trip computer and the fancy looking display.
And also fitted a SP handbrake and the grill vent sliders.
Due to my tyres becoming a bit close to the limit I bought these off a friend to help him out with financial situation....so I put them on the car for the moment...
Then swapped a set of scrap alloys with Mr Scrap man, for a set of these and put them on for laugh....
Drove around like this for a while and then a friend desperately wanted the Lasers for his 306. Came across another set of 306 ‘Swallow’ wheels and good tyres. So they were put on.
Don’t really know if it’s much of an improvement but good tyres and they’re all balanced so going to drive on for the moment. Since then I have acquired a set of the Bohemian alloys from the Roland Garros. I May put them on for a change at some point. I do have my eye on some Siroccos though .
MOT came around and had an advisory for front brake lines starting to perish, so enquired about standard motor factor ones and even some HEL braided pipes, decided on the HELs as they were around the same price delivered to the door. Also changed the brake fluid while I was at it.
Rear brake drums were fairly scabby so I quickly cleaned them off and slapped some black paint on them.
Did fit a Drake Tuning box for a time, worked really well, very noticeable torque and slight power increase. However clutch didn’t like it so I removed it and sold to a lad who wanted it for his 306. I said that there was no guarantee it would work but he tried it and was pleased as punch and paid me up for it. Do believe to this day he still has it on his car.
Lost one of my rear mud flaps so removed the other. Would like to fit another set again at some point and on the front as well. (206s are chronic for flicking mud up the side of the door.)
Another engine light appearance but this time the car let me down. Driving back to university, I was heading up to a town and the engine light came on and also flashed up ‘Anti-Pollution Fault’ on the MFD.
Gauges were fine (I had diesel in it was about just under a quarter) so I kept going and came to a hill, luckily I was going down it, and the car cut out. So rolled into a side road, the car wouldn’t start again. Rung a friend nearby and he towed me to my uni house where I could park the car on the drive. Got my Peugeot planet plugged into the car and it came up with rail pressure low. Didn’t think to check the fuel in the car as it said it had a quarter in it. I’ve driven the car on the light for 20 miles at least before, but anyways turned out that it had not enough fuel in it. Added a gallon and primed it up and it started no problems. So don’t know what that was, but I’ve driven it low on fuel since and it’s been fine. I do know about the pipes under the airbox, I would like a new set but Peugeot want something like £120.
Clutch seem to bed itself back in again and is still fine to this day, really cannot be assed to change it, I will if I have to but the car has done a lot of miles so just keeping it going as much as I can until it either gives up or I spy anything else. Did fancy an SW but we’ll see.
Exhaust fell off one evening…well it hung on just but I thought the car sounded different but I had already got the new parts I was just waiting until I had access to the ramp. The back box I had was a right bargain off eBay…brand new genuine Peugeot. Thing it was for a CC but it fitted fine.
Latest thing to be changed was the turbo pipe (split) & the crank sensor. The EML came on when I was pulling out of a junction and the car hesitated as I pulled up the road. Stuck the computer on it, and it came up with that. I thought it was going to be a right pig to do but the worst part was taking my homemade driver side inner arch off. While I was changing the sensor I noticed that my sump gasket is weeping so that’s going to have to be changed. And also requiring a battery box as my clamp bolt mount snapped and drivers side inner arch however, Harry is supplying these (thanks )
So that’s how the car stands at the moment. Bit long winded but that is pretty much the story of the car and its life with me. And I know it’s not the tidiest of things though bodywork and painting isn’t my cup of tea. Maybe missing the old change and a few pictures but will source these at some point (especially the picture of the pro go kart in the back). Still gets 55-60MPG so I’m happy with it. Future plans are as follows:
• Under door lighting (LED Strips)
• Possible LED strips in the boot (for more light)
• Would like a Second Interior light for the back seats
• New Wishbones maybe at some point (never changed them and rubbers are getting to look worn)
• Either Leather Steering wheel or decent condition standard one
• SP interior door handles (are the rears the same as the front?)
• New front passenger side door rubber (mine leaks if parked wrong in the rain)
• Possible Sirocco Alloys
• Front and Rear Mud flaps
• Tow hitch (To pull my bike trailer)
If you got this far, thanks for reading/looking
Any comments, questions all welcome of course Last edited by southwestchap on Mon Dec 16, 2013 5:14 am; edited 1 time in total
#2: Re: The 206 1.4 HDi Story Author: iainlovatt, Posted: Thu Jul 19, 2012 5:53 am ---- hell of a project well done!!
#3: Re: The 206 1.4 HDi Story Author: adam_w_1, Location: EssexPosted: Thu Jul 19, 2012 5:04 pm ---- Great effort! Very thorough story too.
#4: Re: The 206 1.4 HDi Story Author: Dan-, Location: BiggleswadePosted: Mon Dec 24, 2012 7:51 am ---- Good project not so keen on the droplink bodge
#5: Re: The 206 1.4 HDi Story Author: sicskate, Location: Margate, KentPosted: Fri Jan 04, 2013 7:57 am ---- You can buy a pair of drop links on eBay for a tenner.
#6: Re: The 206 1.4 HDi Story Author: RichardEke, Location: DoncasterPosted: Sun Jan 06, 2013 2:50 pm ---- Really enjoyed reading this was thinking about getting a 1.4 HDI and getting rid of my 1.1L petrol, just the hassle of changing but the MPG of the diesel is very appealing
#7: Re: The 206 1.4 HDi Story Author: southwestchap, Location: DevonPosted: Sun Jan 06, 2013 3:04 pm ---- Glad it was interesting, there's a few bits i need to add to this now.
Mines getting a bit tired now (165k miles) still returns 50-55mpg
Though my cousin's 1.4hdi sw got (no joke) 700 miles to the tank. On a good run and 60/65mph.
#8: Re: The 206 1.4 HDi Story Author: RichardEke, Location: DoncasterPosted: Fri Jan 18, 2013 5:59 am ---- Yeah petrols cant compete with that mpg, i've started having a look they seem to start at £1000, but more are £1500/2000, might have to work hard and try to get one for my birthday or something
My petrols done 85k and is still going fairly well, low insurance and cheap to run was great for a first car but i fancy something with a little more go, cause the 1.1 isnt really an engine, looks &sounds like one but it doesnt really like move anywhere in a hurry
#9: Re: The 206 1.4 HDi Story Author: sicskate, Location: Margate, KentPosted: Sat Jan 19, 2013 12:06 pm ---- My 1.4hdi is only £30 a year to tax, and £335 to insure FC.
Thats about £130 saved a year on tax alone.
#10: Re: The 206 1.4 HDi Story Author: southwestchap, Location: DevonPosted: Mon Dec 16, 2013 5:13 am ---- Well long time with no update to this, the car is still running and driving. Looking at the list that I left ‘to do’ on the original post, the drivers door has a ‘puddle’ light now (recommended). Second interior light installed for the rear seats along with a leather steering wheel. Front SP interior handles installed, Sirocco alloy wheels where put on and used for a while but now back on 306 Swallows, front mudflaps fitted and the tow hitch as well.
The car has had a bit of a check over and tidy up in the engine bay. Inspired by ‘14hdi’ and his baby derv project I shamelessly used his idea on the air filter setup and using a 2.0HDi header tank. EGR setup removed (left plugged in – will get it mapped out when remapped).
Decat downpipe fabricated and installed, and using a straight through backbox (the exhaust note has definitely changed!) Itching to remap the thing now but I fear the clutch won’t hold so that’s going to be on the cards possibly over Christmas. Also thinking that a turbo change might help this thing out (they really are tiny) so currently working on something there. Then this will mean fitting an FMIC. The car really is my daily hack but after driving my VNT 206 this thing really does feel underpowered.
So bigger exhaust will be made up soon as I’m just using the stock one which, really is small.
Couple aesthetic touches that need finishing: passenger door puddle night need fitting and also wiring in the 406 Auto Dim mirror.
Anyways updates need pictures (only a couple though)
Rocker/Inlet off
Yep she’s been blowing
Welded an extra hanger on the exhaust for a bit more support
Downpipe made to fit stock pipe
What it looks like at the moment (the heat shielding has been refitted)
#11: Re: Extracting Power from the Tiny HDi Author: 14hdi, Posted: Mon Dec 16, 2013 6:03 am ---- Looks good, just dropping a comment so I can get email updates
#12: Re: Extracting Power from the Tiny HDi Author: southwestchap, Location: DevonPosted: Mon Dec 16, 2013 6:23 am ----
14hdi wrote:
Looks good, just dropping a comment so I can get email updates
Heh, no worries. Will have to make some changes now in order to have some updates.
#13: Re: Extracting Power from the Tiny HDi Author: southwestchap, Location: DevonPosted: Thu Jan 02, 2014 7:57 am ---- So this happened
Pulled the flywheel as I had suspicions the seal was leaking
Also dropped the struts off to find...
Then (while waiting for parts) started lining up the cooler for install. I know it's not very big but it was cheap so thought I would have a stab at installing it.
Also working on a bigger exhaust, need an evening on the welder to finish that.
#14: Re: Extracting Power from the Tiny HDi Author: commandosqueak, Location: Lower SlaughterPosted: Thu Jan 02, 2014 1:47 pm ---- looking good mate, what intercooler is that?
#15: Re: Extracting Power from the Tiny HDi Author: sicskate, Location: Margate, KentPosted: Thu Jan 02, 2014 2:37 pm ---- Good project, did you make the dowpipe yourself?
I wonder if the 307 1.4 hdi down pipe is the same as the 206?
#16: Re: Extracting Power from the Tiny HDi Author: southwestchap, Location: DevonPosted: Fri Jan 03, 2014 5:16 am ----
commandosqueak wrote:
looking good mate, what intercooler is that?
Not quite sure, I found it at the scrappy in the back of a 106...there's a few 4x4s down there so I'm guessing off something like that.
sicskate wrote:
Good project, did you make the dowpipe yourself?
I wonder if the 307 1.4 hdi down pipe is the same as the 206?
I did have a chap copy my original cat/downpipe and cut the ends off and attach them to the stainless. It's a tidy job but I should of had it made bigger really. Does definitely change the exhaust note with the free flowing rear box.
I reckon they wouldn't be too different tbh, same engine after all.
#17: Re: Extracting Power from the Tiny HDi Author: commandosqueak, Location: Lower SlaughterPosted: Wed Jan 08, 2014 5:19 pm ---- ah ok, will look forward to seeing this progress
#18: Re: Extracting Power from the Tiny HDi Author: southwestchap, Location: DevonPosted: Wed Aug 20, 2014 9:59 am ---- Update to this.
It had its MOT back in July, couple advisories. Drop link boot split, and rear fog light bulb. So that wasn’t too bad.
Have noticed the car is getting a little shabby underneath so before the weather sets in hoping to spray some waxoil around underneath.
Anyways, currently it is up on axle stands with the front end off, fitting an EPAS setup, fresh turbo, intercooler (finally getting plumbed in) and new exhaust.
Will get some pictures over the weekend.
#19: Re: Extracting Power from the Tiny HDi Author: Addaz, Location: SuffolkPosted: Wed Aug 20, 2014 2:03 pm ---- Dont suppose you'd be intrested in a larger 1.4 hdi 16 valve turbo would you? Brand new and un used. It is larger in size but has same direct fitment as yours
#20: Re: Extracting Power from the Tiny HDi Author: southwestchap, Location: DevonPosted: Thu Aug 21, 2014 8:54 am ----
Addaz wrote:
Dont suppose you'd be intrested in a larger 1.4 hdi 16 valve turbo would you? Brand new and un used. It is larger in size but has same direct fitment as yours
Cheers for the offer, but I really shouldn't
Too many other projects that I'm going to sink money into
#21: Re: Extracting Power from the Tiny HDi Author: James3107, Posted: Sun Aug 31, 2014 6:50 am ----
Addaz wrote:
Dont suppose you'd be intrested in a larger 1.4 hdi 16 valve turbo would you? Brand new and un used. It is larger in size but has same direct fitment as yours
How much are you wanting for the turbo?
#22: Re: Extracting Power from the Tiny HDi Author: southwestchap, Location: DevonPosted: Fri Sep 12, 2014 6:10 am ---- Front mount fitted and piped up finally.
It's a bit of a pain on these engines in the 206 as the PAS pump is right in the way
So with a little help from a 106.
Then this allowed me to run my pipes over the front of the engine. Was literally pipework I had lying around from other cars and a leftover FMIC install on the other 206.
Quick test that she held boost.
Need an aux belt now, couldn't find one in my pile so got a custom length on order
Building it back up
Going to drive it around for a bit to see how it gets on with the EPAS then look to fit the fresh turbo.
#23: Re: Extracting Power from the Tiny HDi Author: southwestchap, Location: DevonPosted: Mon Oct 27, 2014 9:04 am ---- The car has been driving fine with the EPAS but with the extra load on the alternator I thought I would add in a volt gauge
and mounted along with the boost one.
Front pads were getting down but finally wore right out, replaced for the moment but I have some 266s to fit.
So this weekend, finally fitted my 1.6HDi turbo thats been sat on the bench for forever and a day.
Bolted up surprisingly well.
Had to modify a boost actuator to fit as the blower came with a Vac operated one. Along with drilling an tapping a take off on the compressor housing.
And back together. Ignore the green wire, was there for test purposes.
Typically the car had no fuel for the test run, queue a very steady drive to the garage to fill up. Probably a good thing to get some oil around the turbo a few times as it hasn't been run for a few months.
Drove it a bit harder on the way back, turbo is more vocal than the KP35 and pulls marginally harder but is crying out for a remap now.
#24: Re: Extracting Power from the Tiny HDi Author: commandosqueak, Location: Lower SlaughterPosted: Mon Oct 27, 2014 11:08 am ---- good stuff mate keep up the work
#25: Re: Extracting Power from the Tiny HDi Author: southwestchap, Location: DevonPosted: Fri Dec 19, 2014 5:35 am ---- Popped up and Steve did his initial fault reading of the car and a few runs to see what the pump and air flow values were.
He then pulled my ECU apart and read the maps off with his kit. Left him to it for an hour or so. Came back and was greeted with "It needs more boost"
Not having a boost controller on me, I adjusted the actuator and got it to around 18-20psi (up from the standard 14psi).
Another run and the car was performing better.
Steve said to leave it with him and he would do some research on pushing the map further.
So went off home happy.
One thing I was never happy with was the size of the stock exhaust. I'm running a straight through downpipe then the stock mid section with a straight through backbox but the diameter is tiny.
So I had a rear powerflow section with a baffled (but straight through) box, so I just needed to make up a front section. So went for a raid through my exhaust pipe pile.
Found something suitable and added a front flexi joint.
Fitted it all to the car but the exhaust tip wasn't quite far enough out, so added an OEM style downturn.
Also modified (with some early morning machining) & fitted the Boost controller and secured that.
Travelled back up to Steve's and had to have a bit of a play with the boost controller as it was pinning a 30psi gauge. Sorted that with some modifications to the spring and got it holding around 21psi.
ECU back out again and steve has worked more magic on it and the car is performing a lot more responsive now. The clutch is hanging on at the moment.
Drove home via minehead to visit a few friends and the MPG has definitely improved.
Top work by HDi Tuning and I will be heading back there again for the next project.
Future plans for the car is a disc rear beam, 266 GTi front brakes, fresh heat wrap on the manifold and downpipe and possibly the higher pressure fuel rail sensor as the limit is quite near apparently.
Cheers for looking.
#26: Re: Extracting Power from the Tiny HDi Author: southwestchap, Location: DevonPosted: Wed May 27, 2015 10:04 am ---- Done nothing apart from drive the thing. Had other projects on the go but the parts stash has grown for this one so a week in the workshop is needed.
Anyways, took it up to the local rolling road.
110bhp / 170lbft
I'll take that for a 181k miles engine/drivetrain.
#27: Re: Extracting Power from the Tiny HDi Author: southwestchap, Location: DevonPosted: Tue Nov 10, 2015 7:07 am ---- So this has undergone a mini to fair overhaul
Its been in the shed for a while and I have replaced:
TREs Inners and Outers
Wishbones
Front 266 Discs and Pads with Calipers
Droplinks
Front Shockabsorbers
ARB Bushes
Front Brake Flexi Pipes
Oil, Fuel & Pollen Filter
Sump Removed and resealed
New PAS fluid
New gear oil
New engine oil
Also
Flywheel Faced and Skimmed (as a test)
So pictures
Subframe dropped, removed the subframe as it was covered in grease and grime
Gearbox needed a clean
Flywheel in the lathe
Refitted
Disgusting how much oil is left in the sump after a drain
Going back together
Not quite finished yet but getting there.
#28: Re: Extracting Power from the Tiny HDi Author: southwestchap, Location: DevonPosted: Tue Jan 19, 2016 8:45 am ---- So refitted and got the car running, clutch was better but would still slip, gave it a couple hundred miles but wouldn't hold from low.
So acquired a 1.6HDi Gearbox and stuck that on along with a Solid Fly and the 215mm(?) clutch. Also changed the intercooler setup to the 1.6 method for OEMness.
With it all fitted, got the car running again and took it for a drive. Immediate improvement, also has the benefit on longer ratios so sits nicely at 70mph on the motorway.
#29: Re: Extracting Power from the Tiny HDi Author: Sim, Location: West CountryPosted: Tue Jan 19, 2016 10:10 am ---- Looks like you kept yourself and thinning pockets busy
What's next in store?
#30: Re: Extracting Power from the Tiny HDi Author: southwestchap, Location: DevonPosted: Tue Jan 19, 2016 10:27 am ---- Yeah just a bit.
More boost after a few miles. Only at 16psi will knock that up a bit.
The heat shielding on the turbo has got a bit wore so could do with replacing that and the centre console lighting seems to of died.
Rear beam is starting to knock a bit. Got a replacement to put on at some point.
But just want to get it back driving again so I can put miles on this rather than my 2.0HDi (Insurance Limits)
#31: Re: Extracting Power from the Tiny HDi Author: Addaz, Location: SuffolkPosted: Tue Jan 19, 2016 4:59 pm ---- You do like to keep yourself busy dont you
That turbo is still sat here, just saying
Side note, I didnt realise you owned a laith?! and was the 1.6 hdi box ma again?
#32: Re: Extracting Power from the Tiny HDi Author: southwestchap, Location: DevonPosted: Wed Jan 20, 2016 9:43 am ---- Yeah, always seem to be taking something apart on one of them. Starting my 2.0HDi 16v engine now.
Haha probably won't VNT this one. I'm not going to push it on any more power. Cheers for the reminder though
Not mine unfortunately, next door neighbour's. Old boy but happy to let me go round tinkering to turn stuff down and anything that requires 'thinking about' he takes it on. Runs a harrison, a myford and a little john along with a bridport(?) mill in his double garage. Right Aladdin's cave.
BE box IIRC
#33: Re: Extracting Power from the Tiny HDi Author: geompj, Posted: Wed Jul 27, 2016 12:07 pm ----
southwestchap wrote:
So refitted and got the car running, clutch was better but would still slip, gave it a couple hundred miles but wouldn't hold from low.
So acquired a 1.6HDi Gearbox and stuck that on along with a Solid Fly and the 215mm(?) clutch. Also changed the intercooler setup to the 1.6 method for OEMness.
With it all fitted, got the car running again and took it for a drive. Immediate improvement, also has the benefit on longer ratios so sits nicely at 70mph on the motorway.
Gearbox from 1.6 hdi 90hp or 109hp? i thought that has a different type of fitment
#34: Re: Extracting Power from the Tiny HDi Author: southwestchap, Location: DevonPosted: Wed Jul 27, 2016 12:53 pm ----
geompj wrote:
southwestchap wrote:
So refitted and got the car running, clutch was better but would still slip, gave it a couple hundred miles but wouldn't hold from low.
So acquired a 1.6HDi Gearbox and stuck that on along with a Solid Fly and the 215mm(?) clutch. Also changed the intercooler setup to the 1.6 method for OEMness.
With it all fitted, got the car running again and took it for a drive. Immediate improvement, also has the benefit on longer ratios so sits nicely at 70mph on the motorway.
Gearbox from 1.6 hdi 90hp or 109hp? i thought that has a different type of fitment
109hp Gearbox. Not sure on the exact gearbox code. 20DM73 seems to be familiar.
I thought it would be different but I took my 1.4 gearbox to a car breaker and offered it up to a 1.6HDi engine which it would of bolted up to. So took a gamble and fitted the 1.6 gearbox to my 1.4 which now drives spot on with the extra power.
#35: Re: Extracting Power from the Tiny HDi Author: geompj, Posted: Wed Jul 27, 2016 3:15 pm ---- Hm...interesting thing. How is it feel with solid Fly? And how much is the power now? On my 1.4 Hdi i run on Gt1544S with FMIC, ceramic paddle clutch and, with the standard turbo 98hp and 251nm...i didn't go to dyno with the new turbo setup... Now, i'm collecting info about changing the engine with 1.6 hdi...or continuing with 1.4
#36: Re: Extracting Power from the Tiny HDi Author: southwestchap, Location: DevonPosted: Thu Jul 28, 2016 7:58 am ----
geompj wrote:
Hm...interesting thing. How is it feel with solid Fly? And how much is the power now? On my 1.4 Hdi i run on Gt1544S with FMIC, ceramic paddle clutch and, with the standard turbo 98hp and 251nm...i didn't go to dyno with the new turbo setup... Now, i'm collecting info about changing the engine with 1.6 hdi...or continuing with 1.4
No real different with the solid flywheel, originally the 1.4 was solid also. up to 110 at the fly. 170lbft torque. On the stock 200mm clutch which was really on it's limit.
I have driven the 1.6, and its hellish pokey. The one I drove on a run on the M5 was on track for 70mpg. Would be quite happy to drive one. I just stuck with the 1.4 for the cheap tax and this one has been around a while so kinda grown attached.
Could push it more now but I don't need to, it drives spot on, i believe I'd need to change the rail sensor to run more pressure and then I'll be up on the limit of what the injectors can flow. So for now I'm happy with it.
Good luck with whatever you choose to do. 1.6 should be capable of good things. Steve @ HDi tuning has got some good figures out of his.
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but I read that it needs to be activated in the BSI...done that and get the light on the dash but still no lights...possibly something to do with the wrong fuse box?
I was very pleased how it drove up and back. I acquired a basic Kenwood radio and thought to use the AUX Out with my iPod as it wasn’t an MP3 radio. Not a fan of cables running everywhere, like it all tucked in out the way but a bit limited with this radio, so lashed this up on the trip.
) and fitted that up...it also had the front fog light function so I thought it’ll be ok for my front fog bumper when I get it fitted.
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