#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)
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