Peugeot 206 - XUD9 VNT Lash Up

[mr_fish]

1st off...yes its a 206, reason for doing so...never actually seen an XUD in one (not saying it hasn't been done) and having a car that doesn’t look much but could also (potentially) light the wheels up in 3rd would be a laugh. Also going for the HDi box to help on the distance runs.

Also I apologise if it’s a bit ‘wordy’ but a lot happened since October. Also trying to get it in the order I have done things takes some thinking about.

So with that in mind....I’ve taken my 1.9D basic 206 and made it a lot better in terms of power. It has taken just over a few months of trial and error, dozens of times fitting and removing the engine from the bay, much bad language and numerous trips to breaker yards but….we finally had the machine driving under its own power.

ALL modifications (including engine change and power levels) be been made known to the relevant parties. Namely DVLA and Insurance.

From the beginning…

I joined the forum and immediately started looking for engines/turbos and a car to put it in.

I like the fact of the XUD9 being a simple engine to modify and maintain and I like the 206.

The original spec:

Peugeot 206 1.9L D

DW8 1.9 Donkey engine (69ish bhp?)
No Positive Manifold Pressure
Hydraulic Clutch
46,000 miles (car and engine)
247mm Front Brakes
Steelies
Dent in Door

Background
Originally I bought an engine on its own (before the car) and started to service that along with painting it Kawasaki green (was bored at the time). The engine is a D8A and had a Bosch fitted as standard originally out of a N reg, Ph1 d turbo with 117k (ish). Unfortunately it had been left out in the 2012 rain showers for a couple of weeks (with no intercooler) so it was slightly full of water. Anyways, removed the glow plugs, cranked it over and it cleared itself out. Refitted and hung some diesel lines to it and managed to get it fired up on the pallet. Ideal, it was a runner.

Video here:




Started to strip bits off the engine (bit of a state), fairly interesting as I hadn’t had much to do with the XUD before.





Then the paint brush came into play, ignore how I was holding the engine up





I did want to change the turbo from a K14 and seemed like the TD04 was the way to go. However, after a few conversations and being teased with VNT videos I started looking for a GT Series turbo....and found one...a GT22v.



Shinys bought at christmas when ECP had offers on



Along with a Gates Kit c/w Waterpump



Removed the Flywheel (New Crankshaft seal purchased)



...and Sump, didn’t have much in the way of Sludge but Cleaned it up



After



Out with the paintbrush (was a bit of a crappy job, but you don’t see it)



Car Found
Found the car on a salvage site where I’ve bought a few from before. A 1998 Peugeot 206 L 1.9D 46k on the clock and had a caved in driver’s door. After a trip to Worcester, it was in the shed waiting for a heart transplant.



The bay...



Hopefully room for a blower back there



Engine was removed, sold to Darren for a 306 he had down there which had thrown a leg. Also took down my Pump and injectors for him to rebuild and modify.



Also had to pick up part of a plough for him



Tried to fix up the 206 auxiliary setup (alternator and PAS pump)



Unfortunately that didn't want to work



Bolted up a HDi box to the XUD and lifted it into the bay.

---

First of many problems to come, the gearbox was sat too high and too far forward. Realised there was a ‘peg’ on the DW8 box that was needed.





Still room for a blower hopefully



Slotted the gearbox mount over to held the drivers side mount



Theres the little blighter - the original K14 just caught up, to see the space available.



Fitted another door and messed around with little bits and pieces but lost a bit of enthusiasm due to the dark evenings and being cold in the shed.



Notice the dent/hole in the sill to be sorted



Standard inlet test fit (for a laugh)



Along with the ‘bigger blower’, clearance is an issue





Xantia Inlet Found + Car
I had the mind to front mount the car already so was looking for a Xantia inlet but instead ended up buying the a whole car. Cat C right off, from a couple cracks in the front and rear bumpers. Anyways it was running a D8B, Bosch and K14 on 91k. All warranty seals and paint over the pump so it didn’t look to have been played with.

Got Lows?



Tractor Spec?



91k Engine



Stripping down





Couldn’t be arsed to scrabble around on the floor



Got the motor out finally, put on a pallet in the corner of the shed and weighed the car in.

Back on turbo clearance and out with the grinder and cut a piece of cross brace out of the bulkhead.

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Ideal...clearance was gained for the blower which I managed to get some turbo adaptor plates made up (again help from Darren there) and bolted to a T2 manifold which I bolted to the engine.







The lower mount was also not inline so a ‘modified’ mount was fabricated, yes welding is a bit of a bodge but its strong enough.



Driveshafts had to be adapted



DW8 ones were too long



Intercooler fitment adaptations to the front panel



Look at that NA tiny exhaust....I know the Xantia one isn’t much better, but it would do for now.

Had a GTI backbox so looked at changing it into something more free flowing as I know that petrol backboxes are restrictive so take one 206 GTI backbox



Cut Open



and emptied



and a pipe welded in..only a bodged job but its stable



Started to test fit the front end with the intercooler. Just using the standard Xantia one..its bigger than the radiator!





Was getting impatient to fit the engine, let alone the VNT, and seeing as I didn’t have, injectors (still awaiting new nozzles) and the turbo wasn’t ready to be fitted. I set in one weekend and started to fit the complete Xantia lump and gearbox into the 206. I did replace the cambelt while it was out for peace of mind. Had to change the VAC pump over as the Xantia had an end cap on the cam.



New seals to be fitted



and drilled out the brass blanking screw (was seized)



Dropped the turbo and inlet off and fitted a new steel inlet gasket.



Offered up the water piping, comparison below

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One job I do not ever want to repeat was the clutch cable conversion. Originally the car had a hydro clutch and if I had thought about it I would've used a DW10 HDi gearbox and a push clutch on the XUD. Because I had bought a shiny new valeo Pull clutch at Christmas I just carried on. Used a petrol 206 pedal, modified it into more of a hook on the end and used the xantia cable.





Changing the pedal was an absolute B***ard even tack welded the nut to a nail to feed it in there because it was so tight. So much bad language that evening.



Xantia gearbox mount needed some alterations with the grinder



There it is sitting in its place



Intercooler mounts



Exhaust was a bit of a homebrew setup. Used the downpipe from the Xantia, 206 powerflow mid section and the hybrid GTI backbox. It bolted up brilliantly.

Started to connect things up and needed to adapt piping and cables, the cooling system used a Vectra header tank along with various offcuts of 306 water piping along with the rear DW8 pipes. The PAS on a 206 has a built in reservoir to the pump and I did try to bolt this up but the holes wouldn’t align. So used a Saxo PAS reservoir and a copper T piece to tap into the low pressure feed.



Had my local hydraulic place make up a high pressure pipe between the 206 power steering pipe and the 306 PAS pump. Had to change the PAS pump on the Xantia motor as it had some setup that worked the hydro suspension.

The car fought all the way with fitting the engine. But we did get there in the end. The intercooler took some fitting as it was bigger than the radiator! The pipes were a bit big really and came fairly close to the radiator. Various piece were chopped out from the fan housing and bumper reinforce. Even had to chop a piece out of the headlights to get them to fit on their mounts. Unfortunately no pictures of this.

So it finally was ready to drive out of the shed.







So the spec of the first engine:

Peugeot 206 1.9 Turbo Diesel

XUD9TE (D8B) Engine (circa 120bhp (at a guess) after Darren fettled)
26 PSI on a K14 - was 21 PSI without extra fuel (Seized actuator)
Pull Clutch Cable Setup
FMIC
91,000 miles (engine)
283mm Front Brakes
Boost Gauge
14" Swallows - Changed to 16” Nimrods when I changed the Brakes
No More Door Dent

Above is a little over statement when the engine was first fitted. As I drove it for a few miles and had the rear liners let go one day, so new wheel cylinders and shoes fitted on the rear. Plus painted the drums up to make its a little more tidy.





Boost when engine first fitted



Custom OEM Style Badge - yes the car needed a clean



307 283mm front calipers sourced and fitted with ‘ehem’ 2nd hand disc and pads (will fit new soon – they’re good enough for the moment).

Comparison



Fitted



With Nimrods





Removed quite a bit of the interior as I sourced a quicksilver one to fit - but that seemed to get delayed (probably because it involved cleaning it first).

Also drove down to cornwall, after a few tweaks and help from the Cornish diesel radger the car found a few extra ponies and smoke.



Had the dent in the sill sorted and the side of the car sprayed along with a sport front bumper.

Drove on then without any issues.

I've just blasted out what I remember so hopefully it makes sense, will read again to make sure it does and update if necessary.

Will continue/update with as it is now (with the VNT turbo and ‘green’ engine) soon…

Must say a huge thanks to Darren for all the pointers and advice he gave, along with answering non stop questions during the conversion and also to the forum projects for their silent encouragement for big boost.

...and if you've read this far...thanks for reading

Watch this space.