#1: Project dirty deezel 1.1 to XUD9TE :D Author: ekjdm14, Location: CheshirePosted: Tue May 19, 2020 6:06 pm ---- 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.
#2: Re: Project dirty deezel 1.1 to XUD9TE :D Author: ekjdm14, Location: CheshirePosted: Wed May 20, 2020 8:33 pm ---- 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...
#3: Re: Project dirty deezel 1.1 to XUD9TE :D Author: ekjdm14, Location: CheshirePosted: Thu May 21, 2020 4:31 pm ---- 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?
#4: Re: Project dirty deezel 1.1 to XUD9TE :D Author: ekjdm14, Location: CheshirePosted: Fri May 22, 2020 5:02 pm ---- 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.
#5: Re: Project dirty deezel 1.1 to XUD9TE :D Author: ekjdm14, Location: CheshirePosted: Sat May 23, 2020 2:06 pm ---- 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.
#6: Re: Project dirty deezel 1.1 to XUD9TE :D Author: ekjdm14, Location: CheshirePosted: Sat May 23, 2020 4:42 pm ---- 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!
#7: Re: Project dirty deezel 1.1 to XUD9TE :D Author: ekjdm14, Location: CheshirePosted: Mon May 25, 2020 5:38 pm ---- 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...
#8: Re: Project dirty deezel 1.1 to XUD9TE :D Author: ekjdm14, Location: CheshirePosted: Fri May 29, 2020 6:01 pm ---- 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!
#9: Re: Project dirty deezel 1.1 to XUD9TE :D Author: ekjdm14, Location: CheshirePosted: Mon Jun 01, 2020 10:06 pm ---- 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.
#10: Re: Project dirty deezel 1.1 to XUD9TE :D Author: David1156, Location: East LondonPosted: Wed Jun 03, 2020 5:49 pm ---- Love this thread, keep the updates coming please!
#11: Re: Project dirty deezel 1.1 to XUD9TE :D Author: ekjdm14, Location: CheshirePosted: Wed Jun 03, 2020 9:32 pm ---- 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...
#12: Re: Project dirty deezel 1.1 to XUD9TE :D Author: Sim, Location: West CountryPosted: Sat Jun 06, 2020 3:58 pm ---- Following this one:)
#13: Re: Project dirty deezel 1.1 to XUD9TE :D Author: ekjdm14, Location: CheshirePosted: Sat Jun 06, 2020 8:09 pm ---- 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)
#14: Re: Project dirty deezel 1.1 to XUD9TE :D Author: Duckworth87, Posted: Mon Jun 08, 2020 6:39 pm ---- 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
#15: Re: Project dirty deezel 1.1 to XUD9TE :D Author: ekjdm14, Location: CheshirePosted: Thu Jun 11, 2020 10:15 pm ---- 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
#16: Re: Project dirty deezel 1.1 to XUD9TE :D Author: ekjdm14, Location: CheshirePosted: Mon Jun 22, 2020 8:53 pm ---- Not a huge deal of progress this last couple of weeks, mainly due to timewasters looking at our Volvo. Decided to keep it for now anyway, last couple of days got on with a bit more of this car, finally got round to modifying the bottom engine mount and got most of the steel top mount made up now, just need a couple of extra bits welded on & that'll be the engine/gearbox positioned solidly.
Also made a start on stripping redundant wires out of the engine bay harness. Initial plan was to do away with the petrol's ECU completely and rewire the ignition switch for the TD, but thought it'll be cool to keep it and use that to drive the original gauges as well as taking an ignition live from it as an extra layer of security, to keep the opportunist at bay since it'll need to see the key transponder to start then.
Will strip the cluster down at some point as will need to place a new redline on the tach face as well as "delete" the engine management light since it'll be setting all sorts of codes from missing/redundant sensors but doing it this way means I'll be able to drive the tach, coolant temp gauge/fans, oil pressure and oil level etc through original wiring. I've got a TD engine loom that came with the engine & will use the temp sensor and glow plug relay part of that, and either run a wire to trigger the GP lamp on the cluster or (more likely) install a seperate lamp for that.
Also got the pump gov modded, tweaked the LDA a little bit for now & back on the engine. Still not 100% convinced the vane pump is working right, but it was running off a lash up of pipes from a jerry can and was sucking air so will reserve judgement on that until it's plumbed in properly. On that note, also jumpered the fuel pump fuse to empty the tank of petrol earlier & flushed through with half a gallon of diesel. Got to grab a couple of gallons fresh and dump that in, should dilute any remaining petrol enough to be going on with. Pics to come, again, when I actually remember to get some.
#17: Re: Project dirty deezel 1.1 to XUD9TE :D Author: gazza82, Location: South BucksPosted: Mon Jun 22, 2020 9:07 pm ---- If you need an mot you will need the engine management light to work ie come on with the ignition and go off ...
#18: Re: Project dirty deezel 1.1 to XUD9TE :D Author: ekjdm14, Location: CheshirePosted: Mon Jun 22, 2020 9:52 pm ---- Hmm, not sure on that one since it'll be mechanical diesel. I suppose being an '03 it'd have to be lumped in with the HDi's on emissions etc so probably would need an "EML" even if it's not managing anything other than the gauges.
I guess I could modify the PCB so the battery charge light operates the EML instead, that'd make it behave in the manner expected of it.
#19: Re: Project dirty deezel 1.1 to XUD9TE :D Author: ekjdm14, Location: CheshirePosted: Sat Jun 27, 2020 3:29 pm ---- Between weather, illness and birthday, made a little more progress. Also spent a day in the scorching heat going over the 180's A/C system and charging it with R290... why do something "stupid" like that? (R290 is better known as Propane gas!), simples, it's a perfectly valid refrigerant used in commercial equipment and on price it's unbeatable, who'd rather pay £50+ for a couple of hundred grams of R134a compared to £30 for a refill of a 19kg bottle of R290? Not to mention it's a much more efficient refrigerant compared to R134a, icy cold air within 5 seconds of startup no exaggeration, and it's legal/proper to vent into the atmosphere so makes future work on the system a doddle. Not recommending anyone else go randomly dumping other gases into their AC without researching first and deciding whether they want to take the chance, but for us it's worth it.
Got the GTi flywheel that I should've kept from the breaker, £30 wasted on stupidity lol but hindsight's 20/20 and was never planning to use the GTi gearbox originally.
Also got most of the engine bay loom sorted now, stripped out wires no longer needed and routed the few remaining sensors to their new homes, got the engine cranking off the key but still need to locate an ignition live for the pump as well as sort out why my reversing light/VSS live is missing. That could be as simple as I've got the wrong ECU fitted currently though, both the GTi and the 1.1 are 3 plug and I grabbed the wrong one when testing! That may also explain no tach activity too, which could've been down to either that or wrong waveform from the diesel CPS, although I'll be going back to the other sensor on the bellhousing when the correct flywheel and clutch is on anyway so it'll all work out in the end.
Think I'll have to get a petrol CTS as the diesel's original gives a gauge reading of about 70c when cold, didn't see that one coming & again, should've hung onto more bits! (I do have a 'plexed HDi lump with all sensors to rob though so may try that before spending).
Engine is now fed fuel direct from the car's tank, still need to mod the fuel filler to accept a bigger nozzle as she's a wee bit tight for the big black hose that'll be shoved in there in future!
Still need to finish the top engine mount, but that's next on the list & when done, I'll be pulling the engine/box back out, cleaning the bay up, fitting the hydraulic clutch setup, GTi header tank, longer throttle cable etc, split engine/box and install flywheel/clutch etc, bolt all the ancillaries and bits to the back of the engine and do the final fit of that assembly.
Then, it'll be onto sorting out gear linkage rods (another "should've kept 'em off the GTi" job, but no biggy as I'll extend what I have), replacing the front suspension/hubs, bleed brakes & fit driveshafts and that'll be all the big mechanical stuff sorted and it'll be time to look at the cooling and induction/exhaust systems. For now, thinking of reusing an old Xantia FMIC as it's "in stock" and just about fits between the chassis legs. Same goes for the radiator, if it holds liquid then an old Xantia jobbie will be grafted in. This'll change once the thing's on the road as both are old and ratty but it'll save a bit of cash for more important (read- fun) items like exhaust pyrometer and boost gauge, 2 fresh tyres for the 180 wheels (the ones with Uniroyals have gone on the blue 180 as it's tyres were shot, plus the wheels are shagged and painted black anyway!) as well as saving time by being able to reuse Xantia pipework. Last edited by ekjdm14 on Tue Jul 07, 2020 11:31 am; edited 1 time in total
#20: Re: Project dirty deezel 1.1 to XUD9TE :D Author: ekjdm14, Location: CheshirePosted: Mon Jun 29, 2020 7:11 pm ---- Gear linkages sorted, engine back out & GTi flywheel/clutch installed, gearbox back on.
Rain/s***ty weather stopped play for now as it's too murky to do much more & I've not sorted the lights out in the garage, tomorrow hopefully will see the pedal box converted to hydro clutch, rest of the bay mods finished & the engine/gearbox prepped for final install if not actually dropped in.
Excitement is building now, feels like most of the faffy custom bits are done now (just the hydro clutch, power steering pump location and exhaust/rad/FMIC mounting on that side of things & it's getting to the point where light can be seen at the end of the tunnel. (still not 100% happy with the pump, the vanes might still be sticking but we'll see).
#21: Re: Project dirty deezel 1.1 to XUD9TE :D Author: ekjdm14, Location: CheshirePosted: Tue Jun 30, 2020 10:58 pm ---- Little bit more done today, what a royal pain in the ballocks it is converting a pedal box from cable to hydro clutch!
Not so much the actual conversion, which was super easy, just chop out the cable guide and a bit of material below it to allow the M/C to poke through & the pedal itself already has a hole in the right place to attach the pushrod. The ballache was all in getting the damned pedal box out in the first place. In the end I lost patience and chopped one of the bolts as it was impossible to get on with the dash in situ, but the struggle continued and it was an epic knuckle-skinner worming it out and back in again afterwards.
Not read the Haynes book of lies on this procedure, but I'm willing to lay good money that it starts with "First, remove dashboard as described in chapter blah..." TBF If I knew I wouldn't have to modify the clutch pedal then I'd have just chain-drilled the box from the engine bay side & punched it out from there! Least I know now.
So, now I'm aching all over from crawling up under the dash with my feet round the b-pillar but the hydro clutch is plumbed up and ready to bleed & managed to give the engine bay and subframe a good clean and shot of gloss black to tidy things up a little. Few jobs to complete on the back of the engine then it can all be dropped in finally, might hold off a few days though as I've just noticed that Royal Snail have my chinabay EGT pyrometer so would like to fit that in the manifold before it all goes in permanently. Good excuse to get on with other bits like going back over the injector pump & swapping over the suspension/brake setup too
#22: Re: Project dirty deezel 1.1 to XUD9TE :D Author: ekjdm14, Location: CheshirePosted: Sat Jul 04, 2020 7:29 pm ---- Last few days have seen the injector pump re-stripped/rebuilt, the vane pump was still a little bit iffy so fingers crossed it's all good now. Managed to break the governor cradle when reassembling last night, fuming with myself about that but fortunately had a spare one already out of a pump. Spec now is-: standard 9mm head/plunger, no cold advance solenoid, 6mm spacer on gov mod & LDA grind to about 7mm pin travel. LDA Spring pretension and pump setup about where it should be, will have to calibrate it properly when it's all together.
Also made a start on working out the alternator and PAS mounting points, thinking at the moment Xantia alternator body with 206 reg/rec & brush pack, mounted to standard Xantia mounting point & PAS pump below that on brackets brought out from the former AC pump mounting. Waiting on time and weather to align such that I can get the engine finally fitted now, rain sucks!
#23: Re: Project dirty deezel 1.1 to XUD9TE :D Author: ekjdm14, Location: CheshirePosted: Mon Jul 06, 2020 9:35 pm ---- Well the exhaust pyrometer arrived today, so got on with fitting that. Bit of a ballache as I lost part of the compression fitting & had to spend ages making a replacement out of an M10 bolt.
Worked out well in the end though so that's in, boost controller fitted & managed to get the coolant tank located (due to space constraints, gone with the GTi tank relocated in the plenum area behind the front strut), steel top engine mount pretty well finished too. Engine is now mounted properly & just needs the intake/exhaust and cooling system piping up, one gear linkage extending a tiny bit more, ancillaries bolted on & wiring plugged in then it'll be time to move onto swapping the suspension/brakes. Good couple of days work and it'll be ready for a test rip providing nothing else unexpected crops up.
Really, REALLY must get some photos too!
#24: Re: Project dirty deezel 1.1 to XUD9TE :D Author: ekjdm14, Location: CheshirePosted: Wed Jul 08, 2020 8:51 pm ---- Damned rain set in this afternoon so no camera out, but I was on a roll piping up the cooling and induction systems. Got most of the pipework sorted, cooling system just needs a couple of small bore bleed lines making up and the intercooler plumbing is worked out back to the hot side, I'm just missing one Xantia hard line to finish that setup (not sure how I've ended up not having it, thought I had everything from our old white car!).
Wiring is mostly plugged in now, just the VSS/reversing light feed to sort out & I think I know where it will come from, plus glow plug controller and an ignition live to be worked out.
Found out that the alternator/PAS pump bracket from a DW10 lump can be persuaded to fit the XUD block with some minor alterations to clear the fuel pump bracket and oil cooler lines so that's made mounting up the alternator and PAS pump in line with the crank pulley a doddle, saved a couple of hours fabricating brackets from steel plus gained me an auto-tensioner into the bargain.
Not a huge amount left to do on the engine/gearbox installation now, sort out either a replacement (or weld up a steel version) for that last boost pipe, a few brackets to knock up for the Xantia radiator and FMIC, modify a slam panel/fan assembly to squeeze in somehow & that gear linkage to extend then it'll be onto the rolling stock and interior assembly. Very much looking forward to some drier weather to allow me to get this beast rolling now, it's all starting to come together at last
#25: Re: Project dirty deezel 1.1 to XUD9TE :D Author: ekjdm14, Location: CheshirePosted: Thu Jul 09, 2020 4:20 pm ---- Few more jobs ticked off the list this arvo, throttle cable made up and installed. Need to do something about the pedal travel as it's not quite enough to pin the lever on the stop now (although not far off and likely would on a standard pump).
Gear linkage also sorted, some more wiring attended to (what a pain in the a**e, Haynes is chocolate teapot on this & the number codes are really hard to read where they haven't already rubbed off. going to probably end up rewiring the reversing lights old-fashioned stylee as the switch ain't talking to the BSI, fitting an aftermarket tach & working out why the ABS light is now on (I may have unplugged the front sensors while the engine was out, can't remember now!).
Also finally got the clutch pedal attached to the M/C while I was under there playing with the throttle cable. Definitely true the last 10% of the work takes 90% of the time. Taking a well earned rest now & flicking through the Book of lies AKA Haynes, like it'll do me any good lol.
#26: Re: Project dirty deezel 1.1 to XUD9TE :D Author: ekjdm14, Location: CheshirePosted: Fri Jul 10, 2020 7:14 pm ---- OK will have to get photos in a sec this is getting ridiculous! Starting to look like a car again now, clutch bled, Glow plug relay fitted, Xantia radiator and FMIC mounted and mostly plumbed in, slam panel hacked up to hold them & cooling system test-filled with water... It leaked like a sieve... One of the pipes down the back of the engine typically, but will look into that when I start on the next phase which is changing the suspension/brakes over to the GTi coilovers.
Still got issues with the damn multiplexing, from the bits I've lost it's looking like a VAN line problem. Will have one last ditch effort comparing things to the 1.4 8v & trying to interrogate it through Planet when I can be arsed, but otherwise I'll just go with a standalone tach & wire the reversing lights and wipers old-skool. Can't wait for the first test drive, should be great fun.
#27: Re: Project dirty deezel 1.1 to XUD9TE :D Author: ekjdm14, Location: CheshirePosted: Sun Jul 19, 2020 9:18 pm ---- Oops, no piccies but she's back on all 4 wheels now! Coolant leak was the water inlet housing, got a replacement one for 6 quid and that's all holding water now, drain down after a week or two on the road to pressure test it and add actual coolant if it behaves itself.
All my wiring seems to check out OK so thinking there's an issue either with the COM2000 unit or maybe a fuse blown (thanks to an old thread by Vortechs I noticed that the radio shares a fuse with the COM2000 and guess what I'd just removed when the issue arose! Never noticed any sparks but it was an aftermarket hack-in and like Vortechs, I'm not big into coincidences.)
Once that issue is fixed all that needs doing is bolt the seats in, sort out the last boost pipe when it arrives, bit of clearancing on the intercooler brackets so the headlights can go back in properly, get a shorter aux belt, cutting the bumper and crash bar to fit and an oil change + bleed the clutch better (It has officially moved under it's own power back and forward on the drive, clutch bite is on the floor though!). Oh, and adjust the exhaust as it's rattling like buggery and fouling the gear linkage in 1st/2nd.
It's getting exciting now, the project's coming to life at last. This will be "stage one" of the project at least. Once we've got some miles on it then stage 1.5 will be swapping in the GTi rear beam and making it cosmetically nicer at the front end. Eventually the plan is, once we've eaten through this turbo (only a little K14), stage 2 fabricating a new exhaust manifold to relocate the turbo to over the gearbox, relocating battery to the boot & going with a VNT turbo of some description.
Depending on how the engine as a whole holds together, I'm also in the background starting to plan out a big-power big-torque XUD build (this one will be more top endy with the KKK turbo) that may or may not end up in this car. Something along the lines of DW10 rods/shells, slightly lower comp pistons, head studs & ported possibly look into a 12v head & maybe even compound turbos or twin-charged with a Roots blower into a big turbo. Dreams of the future though, for now it still needs finishing to such a standard that it can be got through an MoT (will entail fitting a cat shell in the exhaust, sorting the EML behaviour and turning the juice down/limiting the revs to 4k and presenting it to be tested as if it were a 2.0HDi, since it's too late a model to test as DW8 I think)
#28: Re: Project dirty deezel 1.1 to XUD9TE :D Author: ekjdm14, Location: CheshirePosted: Mon Jul 20, 2020 8:47 pm ---- Well well, the better half got some photos earlier so will post them up when I get the email through!
Car now has it's face back on, looks surprisingly stock too which is kinda cool, haven't cut the bumper too much but did have to modify the headlamps to get them to fit back on. The VAN issue was not a blown fuse sadly, but will break out diagbox tomorrow if I get a chance. Also got to go find a 90* 2" rubber elbow and some hose clamps since we got let down by an eastern european supplier for the last charge pipe we needed & I've just knocked up a temporary one to get us by till we find one to suit.
Engine runs better each time I fire it up now, just frustrated at the VAN problem.
#29: Re: Project dirty deezel 1.1 to XUD9TE :D Author: ekjdm14, Location: CheshirePosted: Fri Jul 24, 2020 10:41 pm ---- Hmm, forum vanished for a while and have lost some pics but here's one from the other day. The car is now officially on the road, although far from being finished.
I got plain fed up chasing the wipers/lights issue, the BSI is able to actuate them and it can see the inputs from the COM2000, including the key chip, but for some reason the ECU is showing as unlocked but the BSI remains resolutely locked. Rather than faff round swapping BSI/ECU sets (although I did have a half hearted go with a set we had around) I've just circumvented all the electronic BS now and wired in the dip/main beams on seperate switch/relays (keeping the main beam flash on the stalk) and done the same with the wiper motor high/low speeds & made a plate to go where the radio would've been housing the controls for these and the glow plug button.
This has got the car to a point where it's driveable, although still need to do a lot of rewiring for other bits and arrange some standalone instrumentation plus add a cooling fan. Only done a couple of pulls so far but my butt-dyno says around 160bhp already with barely any fine tuning done. When it's in a state that it can sustain it's temperature at a standstill and it's been shaken down/tuned a bit more we'll look into a dyno session to see what it's really capable of with the big old Xantia FMIC hanging out of it's face!
#30: Re: Project dirty deezel 1.1 to XUD9TE :D Author: Sim, Location: West CountryPosted: Sun Jul 26, 2020 9:02 am ---- Coming along nicely!
ekjdm14 wrote:
I got plain fed up chasing the wipers/lights issue, the BSI is able to actuate them and it can see the inputs from the COM2000, including the key chip, but for some reason the ECU is showing as unlocked but the BSI remains resolutely locked.
I couldn't work out where exactly you can see the "BSI locked: yes" message. I can only recall "ECU locked" in the Immobiliser status of the BSI Parameter Measurements submenu. Or are you assuming BSI is "locked" because of wipers etc? Car is not in economy mode by chance?
What does the ECU "Parameter measurements -> Standard parameter measurements" say under the "Control unit condition"? Note that such selection might not available under every type of ECU, but sometimes can be brought up when lying by choosing a similar engine family instead of the one your car physically has (use at your own risk, but in my experience if the ECU chipset is significantly different, it won't even reply).
If "problems detected while transmitting the unlock code" item shows no problems, then BSI can talk to the ECU (and that is confirmed already by immobiliser working/recognising key and ECU being unlocked), so your problem is not in the dreaded yellow/white CAN bus wire pair connecting the two (unlike it was in my case of 1.4 HDi).
If you want to dig deeper, I would need all the make and software versions of BSI and ECU of yours and could ask the "friends" over at the digital-kaos that I made while resuscitating the cursed HDi of mine.
#31: Re: Project dirty deezel 1.1 to XUD9TE :D Author: ekjdm14, Location: CheshirePosted: Sun Jul 26, 2020 9:46 am ---- The message I was seeing was "BSI unlocked-: no" IIRC, on the same page as the "problems transmitting" one. (also have ECU and BSI matched-: yes etc etc)
From planet, the BSI is indeed talking to the ECU as it did show "ECU unlocked-: yes". Also can/could actuate wipers/dip and main etc from the actuator test in the BSI menu, and in the COM2k menu I could see the input states changing for the wiper and light switches. It is now in eco mode, although wasn't to begin with when the issue arose. It's like it's all talking but the BSI seems to be having a hissy fit.
I will try and find a minute to grab the BSI and ECU info later just in case there's any light could be shed, would also appreciate if with that info they could give me the plug/pin info for the rev counter since (ably assisted by Haynes) I must have pruned that out as "not needed" and having tach input would at least kick it out of eco mode as well as saving bother of chopping the instrument panel up and fitting a Xantia tach behind the face!
Cheers.
Oh in other news, I think we're experiencing a need to grab a set of refurbed injectors sooner than planned. On a couple of occasions we've had the engine start clattering/missing heavily on one cylinder and smoking in a way that screams p**sing injector to my mind. It clears after you give it a couple of good blips but not exactly conducive to fun driving when it happens. also must find time to swap in the lowered GTi beam as it's got a rake like an old muscle car at present!
Will get back with the BSI/ECU particulars when I can, much appreciated.
#32: Re: Project dirty deezel 1.1 to XUD9TE :D Author: Sim, Location: West CountryPosted: Sun Jul 26, 2020 2:31 pm ---- Hmm I'm now curious about the read-outs of these 3 pages:
And BSI parameter measurements (live data) of the camshaft/crankshaft sync, as well as whether there's a correct report the engine RPM.
Tacho data arrives to the BSI via the CAN bus packets, and is then directed to the dash to drive the needle.
No hard promises from the digital-kaos folk, as most of them just suggest a reflash of everything with a dump that they've got at hand, but worth a try:)
#33: Re: Project dirty deezel 1.1 to XUD9TE :D Author: ekjdm14, Location: CheshirePosted: Sun Jul 26, 2020 3:36 pm ---- I'll have a look when I get a chance, but the immo. etc are OK, there won't be crank/cam sync as the 1.1 never had a camshaft sensor but I'm seeing 0rpm whether engine is running or not hence wondering about the wiring from CPS to ECU since it appears the ECU is communicating but it's not getting it's signal from the CPS
(assume the speedo and temp gauge are also driven through the CAN line between ECU/BSI too and they both work until the dash goes to sleep).
Cheers.
#34: Re: Project dirty deezel 1.1 to XUD9TE :D Author: ekjdm14, Location: CheshirePosted: Sun Jul 26, 2020 7:32 pm ---- OK had a quick sanity check earlier to make sure the CPS was still working (it was when I fitted the GTi 'box but you never know!). There's about 380 ohms across the sensor, measured at ECU end and with the engine running my multimeter sees a varying AC voltage around the 5v area so sensor appears good and has continuity to the ECU end.
The only bit I'm unsure (not 100% anyway) is if I've got the thing wired to the right pins. It should be, there was only ever 2 twisted pairs in the ECU harness. Obviously the one on the middle plug is the CAN line and the other one should be the CPS. If that's the case then I have no clue what's going on, although it is possible that the ECU itself is dodgy too (car ran OK when we got it and chucked a BSM in it, but we only ran it a couple of days & the ECU has been opened by someone at some point as it's got blue Hylomar all round the lid...)
To be honest the more I think about it, the more I like the idea of opening up the BSI and modifying the supply to the relay so the dash stays awake & just go with my own tach like I'd originally planned anyway.
If I was to start this project from scratch I think the only thing I'd change is I'd start with a pre-plexed car. It's a good enough system when it's standard or close to, and I love the coding options with PP2K but for this kind of swap it's a royal b***h! (also using a pre-plex DW8 car as a base would mean simpler times at the MoT station). All good fun though and the shell is nice and shiny!
#35: Re: Project dirty deezel 1.1 to XUD9TE :D Author: Sim, Location: West CountryPosted: Mon Jul 27, 2020 9:10 am ---- A couple of internetz places suggest to re-program/re-learn the key transponder chip.
Virginising BSI would be the last resort. I told you those guys just want to reflash everything:))
If I remember correctly, there is also a PP2000 option to "Reinitialise BSI configuration", or something along those lines, but I never tried to use it. Would that also mean that one has to write down all cfg settings prior as a backup?
#36: Re: Project dirty deezel 1.1 to XUD9TE :D Author: ekjdm14, Location: CheshirePosted: Mon Jul 27, 2020 11:13 am ---- Yeah I thought that, resync'd the key and remote locking works but don't think we have the code to reprogram it.
I suppose reinitialising the BSI could work, but think we'd need the key code for that too probably? In all honesty I'll probably just rip the thing apart and feed the dash and heater blower relays with an IGN permanent live since that's the only bits we really *need* for the car to be reasonably driveable now.
We'll get there in the end either way.
#37: Re: Project dirty deezel 1.1 to XUD9TE :D Author: Sim, Location: West CountryPosted: Mon Jul 27, 2020 12:41 pm ---- I wish I had seen this video on how to obtain the BSI PIN etc before I dished out £24 to the stealer:) www.youtube.com/watch?v=nXoUz-ejRtI
I reckon that carprog bit of kit would've paid off by now..
So throwing this in in case you'd reconsider or someone else reading this thread.
#38: Re: Project dirty deezel 1.1 to XUD9TE :D Author: ekjdm14, Location: CheshirePosted: Wed Jul 29, 2020 10:03 pm ---- Cool, I may have another route to try since we've made the decision now to break the '06 1.4 Verve so might pilfer the BSI/clocks/ECU etc out of that and see if it behaves any differently.
For now, I'm happy to just go about the no-plex rewiring. Got the reversing lights back today (and added an LED reversing floodlight to help with the tinted windows at night situation!), added a boost gauge that works and turned the wick up a little. Got rid of the single-line MFD as the bulbs were all gone and it only cried ECO anyway so useless as a clock. Boost gauge and eventually oil pressure and working EGT will live in the shroud.
Now running around 22-25psi depending how hard you push it & not too much smoke, it really shifts for a square-port on a K14, better than expected. When we have a proper cooling fan solution (surprisingly it's not really needed it yet, benefits of running the big Xantia rad and FMIC in such a light car I suppose) will see about booking in at a local dyno just out of interest although it feels great so that's good enough. If I had to guess it must be around 180-190bhp currently though, not bad for a 27 year old diesel engine running on vegetable oil and about a tenner's worth of actual mods.
#39: Re: Project dirty deezel 1.1 to XUD9TE :D Author: ekjdm14, Location: CheshirePosted: Fri Jul 31, 2020 9:15 am ---- Well the project may be taking a turn for further mods after last night, after doing a couple of pulls adjusting the boost the throttle pedal stuck on the silly plastic stop thing & in the moment I shut the engine down. After sorting the pedal and restarting, the turbo suddenly was not at all happy. No bad noises or oil burning but definitely no more boost and can't hear it whistling away at idle any more, not had a proper look yet but I'm calling it as either the shaft sagged due to hot-stopping it or (this one less likely but I hope it's this!) perhaps it cooked the oil in the bearing and it's nipped up in carbonised crap.
either way, it's looking like a TD04 or similar will be happening sooner than later, for now I'll be off out to sweat in the heat shortly and see if I can resurrect the K14 at least for the moment. Oopsies... lol
#40: Re: Project dirty deezel 1.1 to XUD9TE :D Author: ekjdm14, Location: CheshirePosted: Fri Jul 31, 2020 12:28 pm ---- OK here's the damage...
Turbine wheel has exploded, not sure if it went when the throttle stuck or just before since I was surprised the engine didn't rev to the moon as soon as it stuck so maybe it was a blessing in disguise that saved the bottom end from a 7k+ buzzing. Whichever came first, sticky throttle or exploded turbine, the turbo is dead. Long live the turbo...
EDIT-: further to this, we returned to the scene of the crime in the 180 earlier & recovered more chunks of turbine wheel from the ground, a good 50 feet before I let off and realised the throttle was stuck. So, it was indeed a blessing in disguise, the turbo failed just at the end of a pull & in doing so has prevented the engine reaching stratospheric revs when the throttle stuck. Not all bad news then, and a narrow escape for the engine!
#41: Re: Project dirty deezel 1.1 to XUD9TE :D Author: ekjdm14, Location: CheshirePosted: Sun Aug 02, 2020 1:07 pm ---- A decision has been made... After a little looking around at various compressor maps and comparing what people on the 306 forum have been doing, we landed on the GT2056V as a decent fit considering power expectations, cost and to a lesser extent sound.
Anyway we happen to have sat, unused on the drive awaiting tidying up and selling on, a 2006 Volvo S80 D5 and I don't think it'll take an expert to guess just which turbo they happen to run.
Being a Volvo, there's plenty of room behind the engine to work so (be it right or wrong!) decision made. In the interests of a timely repair to the 206 I'm stealing the turbo from the big Swede, to be replaced at a later date. That'll be some sweat but save on delivery time and budget, and looks like it'll fit in the standard location too so not too much fabricating to get it on. will have to work out nozzle actuation as it's vacuum controlled on the 2056 and will need to be boost controlled in this application but I think I can either modify the can to work backwards or use an actuator off something else.
Watch this space...
#42: Re: Project dirty deezel 1.1 to XUD9TE :D Author: ekjdm14, Location: CheshirePosted: Mon Aug 03, 2020 12:22 pm ---- OK decision reversed! Just about to start ripping into the Volvo and had a last look at ebay, a 2052V with shaft play was on, £40 with 24h delivery & a bearing/seal kit £25 also fast delivery. These should save a bit of sweat and we'll have a running Volvo still haha.
few more bits arrived earlier, warning lights for dip/main beam and oil pressure gauge so will get those and some other bits done while we await the snail...
#43: Re: Project dirty deezel 1.1 to XUD9TE :D Author: Sim, Location: West CountryPosted: Fri Aug 07, 2020 12:08 pm ---- Turbo failure while working on an involved mod? 5 words: break things to make things!
#44: Re: Project dirty deezel 1.1 to XUD9TE :D Author: ekjdm14, Location: CheshirePosted: Fri Aug 07, 2020 10:28 pm ---- Indeed, if it breaks it was meant to be upgraded...
Got a bit carried away the last few days and bought 2 306s in the space of 36 hours so been playing a bit with those, Ph2 5dr DT is MoT'd so will get a little use and Ph3 cabriolet with supposed cooked engine (that was a missing fan switch) needs a few bits for MoT after sitting 2+years but will clean up nicely. Back on the 206 tomorrow afternoon though hopefully, £40 GT2056V has only mild in/out play and not oily but I have a bearing kit here so may as well refresh it before it gets worked into the car.
What's next improvement to need doing, driveshafts or lift the head on boost?
#45: Re: Project dirty deezel 1.1 to XUD9TE :D Author: southwestchap, Location: DevonPosted: Thu Aug 13, 2020 7:15 am ---- If you put a VNT on you will need ARP headstuds. Could probably get away with a bit more torque out of the originals, I've done it to see what would happen, but in the end swapped them out one by one. Held around 22PSI of boost and that pulled just shy of 200hp on a GT2256v
Plenty of room down the back of a 206 for it.
#46: Re: Project dirty deezel 1.1 to XUD9TE :D Author: ekjdm14, Location: CheshirePosted: Thu Aug 13, 2020 1:54 pm ---- Hey man thanks for coming back to me on this This swap is partially your doing & partially another guy locally who had a DT swapped 206, causing a serious bout of inspiration and "how hard can it be"-ness... (It can be quite hard as it goes, like you said in your thread i think, it's the little bits that get you!
Anyway bit of an update, found a K14 turbine shaft in the garage & decided in the interest of getting the car going quicker I'd clean up the turbine housing and repair the original snail for the moment. So last Friday it was back on the road with the boost wound down to about 20psi to stop us from overspinning the thing again lol.
And then 2 of the injectors started leaking fuel like a sieve for some reason. Half a tank in 20 miles... Thought it was the leak off pipes to begin with although it seems to be from the actual injector bodies where they screw together. This coupled with wanting to get everything ready for MoT time end of September (screen wash button, telltale lights, cooling fan and exhaust system etc) has led to us swapping the insurance over to the DT 306 for now to allow work at my leisure.
It'll be back soon though, it went too well to not want to continue & will be aiming for roughly similar power to yours. The way we make the power though shouldn't tax the head bolts too-too much as its not going to be a torque monster, aiming to make the power higher up the revs to better use the GTi gear ratios. It accelerated like a scalded cat with it's ass on fire when the boost kicked in, great fun.
As far as room for the VNT it does look like it'd fit down the back just fine, it's not much bigger than the K14 just wider, but will probably gearbox mount it to create more space for keeping the gear linkages and bulkhead cool (could feel the heat through the footwell and the gear shift bushes are starting to suffer already) not to mention the current manifold is the old squareport type and restrictive so a homebrew tubular one would be nice & it gives easy engine-in access to the VNT can because I'm sure I'll run into similar issues as you did trying to work it off boost instead of vacuum.
Incidentally what did you end up with as regards that, did you add a nipple to the other side of the can & feed it pressure through an MBC? (that's what I'm currently thinking of doing) or did you end up with a traditional WG actuator and from what?
Thanks, Dan.
#47: Re: Project dirty deezel 1.1 to XUD9TE :D Author: southwestchap, Location: DevonPosted: Fri Aug 14, 2020 5:38 am ----
ekjdm14 wrote:
As far as room for the VNT it does look like it'd fit down the back just fine, it's not much bigger than the K14 just wider, but will probably gearbox mount it to create more space for keeping the gear linkages and bulkhead cool (could feel the heat through the footwell and the gear shift bushes are starting to suffer already) not to mention the current manifold is the old squareport type and restrictive so a homebrew tubular one would be nice & it gives easy engine-in access to the VNT can because I'm sure I'll run into similar issues as you did trying to work it off boost instead of vacuum.
What size exhaust are you running? I made up a 2.5" full straight through all the way from the turbo and didn't have any issues with heat. Exhaust is nigh on half the restriction for turbos, I ran just the downpipe for testing purposes on the dyno and picked up 17hp.
Yes I planned to move the turbo but in the end I had done what I wanted with the car so I moved the engine into a 309 for a while until I decided to swap to a HDi. Would make life easier with tweaking the stop screw and ensuring the actuator rod is in the right place.
ekjdm14 wrote:
Incidentally what did you end up with as regards that, did you add a nipple to the other side of the can & feed it pressure through an MBC? (that's what I'm currently thinking of doing) or did you end up with a traditional WG actuator and from what?
Did try and force boost the other side of the vac can but didn't work as well as I hoped. So just took a stock wastegate actuator from a TD05 I had kicking around. Had to do something fancy with the mount. Didn't look pretty but it worked well. There is a photo of it mounted on the 306 forum I believe. I tried the MBC route and yes it worked it wouldn't drive happy on cruising....fine if you kept it on song but when on the dual carriageway it would spike a 60psi EMP gauge
So swapped out to a electric boost pressure switch which would open an inline valve (think it was an XUD EGR one) was a bit fierce at times but seemed to work well.
#48: Re: Project dirty deezel 1.1 to XUD9TE :D Author: ekjdm14, Location: CheshirePosted: Fri Aug 14, 2020 1:03 pm ----
southwestchap wrote:
What size exhaust are you running?
What's a downpipe? lol but honestly it's been running straight out of the elbow for the time being, and had previously noted your comments about how restrictive exhausts are so was planning a side-exit as wide as possible probably 3" or 3 1/2"
ekjdm14 wrote:
Incidentally what did you end up with as regards that, did you add a nipple to the other side of the can & feed it pressure through an MBC? (that's what I'm currently thinking of doing) or did you end up with a traditional WG actuator and from what?
Did try and force boost the other side of the vac can but didn't work as well as I hoped. So just took a stock wastegate actuator from a TD05 I had kicking around. Had to do something fancy with the mount. Didn't look pretty but it worked well. There is a photo of it mounted on the 306 forum I believe. I tried the MBC route and yes it worked it wouldn't drive happy on cruising....fine if you kept it on song but when on the dual carriageway it would spike a 60psi EMP gauge
yeah that's what I feared, having only K14s around means a bit of scrap yard shopping required there then. 60psi EMP wow, not really au-fait with exhaust pressure issues but would that be creating the hotside equivalent of compressor surge? (not to mention poor gaskets!) Think I best get a second pressure gauge and read up on that side of things
So swapped out to a electric boost pressure switch which would open an inline valve (think it was an XUD EGR one) was a bit fierce at times but seemed to work well. so basically no pressure to the actuator until a threshold reached & then it'd shuttle on/off in a semi-PWM kind of fashion to control boost in a few psi window?
Thanks again, will have to look up the 306oc post with the actuator setup but I think I can visualise what you mean hopefully.
#49: Re: Project dirty deezel 1.1 to XUD9TE :D Author: ekjdm14, Location: CheshirePosted: Thu Oct 08, 2020 1:14 pm ---- Been a bit quiet on the dirty deezel front for a while, just been running it with the rebuilt K14 and lower boost for the time being since it made an exhaust system for MoT purposes easier to knock up (pretty much all standard GTi system with the inlet lopped off and a TD one welded on, cat gutted and O2 sensor bungs welded up).
It's been pretty reliable as far as not leaving us stranded, but now the MoT is out and it's time to address how to get it tested. This is going to mean a slam panel made from steel (the chopped about original PA/GF item is cracked around the catch area now), the wiring needs tidying up and shoving in some loom tape & then the kicker, it's suddenly decided to throw an ABS code for both front sensors incoherent signal...
This coupled with the fact we now have 2 306s and recently bought a £50 SW with a cooked engine means things are progressing slowly, it will be back though
#50: Re: Project dirty deezel 1.1 to XUD9TE :D Author: ekjdm14, Location: CheshirePosted: Wed Jan 13, 2021 10:46 pm ----
Just plopping a couple of pics of the latest project here, can't work out how to upload them online other than here lol
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