Peugeot 206 - XUD9 VNT Lash Up

[mr_fish]

Part 2

Well after 2000 odd miles of happy motoring and an itch for more power it was time to drop the motor. Well Darren said he could spare an afternoon for turbo fitting so I started to take the engine out ready for this. Also when I say no issues...think I could be a member of team orange sump.



The pipe under the stat housing split and was weeping out and down the block. No raised temps just losing a drop of water. The engine was coming out anyways to be rebuilt so that didn’t worry me too much.

So the strip down







In keeping with my interest of OEM’ness. I found a intercooler for the 1.6HDi 206 and tried out the test fit before removing the engine. Couldn’t find a front cowling from a 1.6HDi (they seemed to always be smashed up) so modified my own setup. Also more piping was bought.





Intercooler was sat too high really so some modification to the lower cross member is needed





Something like this I was thinking



After faffing around with that I got the engine ready to lift out.







And back to basics



Two XUD lumps, green one waiting for fitment



Had my oil line ready



Was going to use the T2 exhaust elbow, pretty damn restrictive though so next door chappy helped make up made up a fresh piece to bolt to the turbo





Exhaust plate and manifold machined a little bigger out to match.


Plan’s for the exhaust off the turbo

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Being a little behind the green engine didn't have a cambelt, pump, injectors, inlet, turbo, alternator or PAS pump fitted. Pretty much a bare block. Mega thanks to Chris and Ruan for helping fit that while Darren played with the turbo.



Did have a moment when Darren got excited and seem to of lost two of the locator dowels for the vane control luckily next door neighbour had some needle roller bearings which we chopped down and used.



Bits bolted on



Theres the ‘lads’ busy. Also had to fit the ARP ‘win’ studs from zx_volcane. Wasn't going to initially buy them but I was told that the turbo wouldn’t be fitted if I didn’t (haha). Also Ruan’s famous VNT impressions from his car always ended with “...and the coolant light came on as I lifted the head”. Suppose I’m not really a fan of headgasket changes when their in the car.





Quickest engine fitting I’ve seen.





The derv crew stayed until around 11pm that night to get the car running (which I’m hugely grateful for). As the engine hadn’t been turned over for 6/7 months, also the pump and injectors hadn’t been run since they were rebuilt. So with a couple people there to assist IF it did take off, was helpful.

I’m kicking myself for never recording the 1st start video as it was quite entertaining. Nearly all valves were stuck and no ether to help her out. So was seriously down on compression we lashed some WD40 down her throat. Eventually a few let go and built enough compression to get her to fire. All running fine bar a bit smokey and a leak from the stat housing.

Thermostat leaking issues



New seal from peugeot, still leaking. Did notice a little bit of the aluminium had worn away so replaced the whole housing with one from Poodle. Seemed to have done the trick now.

All a bit tight back there, not really a fan of the water routing



Had a plumber friend who made up a new bit of pipe for me. My explanational drawing.



Needed to get an exhaust fitted so...off the turbo.



Welding was tidied up afterwards



Alot of people will cry at the air intake, I know Ruan and Darren are



Another shiny to help reduce the engine movement



Well from when the cornish lads helped fit the engine I loosely built the rest up and took it for a quick drive. Honestly couldn’t see what the fuss was about for the VNT lark. Smokey, laggy, pinning the 30 psi gauge....I knew there were issues. The vanes weren’t opening. Basically the VAC can didn’t like to work the other way around so couldn’t do much with the engine in the car so out it came again. Was able to tidy a few things up then, namely piping. Fitted a better can and started to lift the engine back in.

Had the machine man make me up a tall engine mount bolt. For when we slotted the drivers mount forward for clearance.





Was toying with wheels courtesy of Jimbo



Bit tight in my opinion



New water pipe made

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Also fitted the coilovers I got from Sam. Many thanks to Ginge’s guide as i was wondering how to piece it together.



And fitted, even managed to save the droplink.



Engine back in and fitted the Red engine mount



Severe lack of photos then. But got the car back together on its wheels



Hellish problems with getting the vanes to open with the boost still. In the end found out it was the MBC being too closed up, but the actual spring inside had coiled up. Sorted that and went for a drive. Was really pleased to see the gauge stop at 15psi and OH MY GOD it was an absolute ANIMAL. Can definately relate to Ruan’s VNT noises now!

Upped the boost to a safe 20psi and it was insane...well coming from a K14 which you literally had to strangle the sod to keep ‘er blowin. This is whole different drive. From the moment your foot is in the shagpile, the power is there and a definite huge increase in torque. By the way, this is still with my hellish restrictive inlet. When I sort that out, I swear something is going to break (though i don’t drive hard all the time). Also when you come to a hill, no need to drop a cog, as long as you don’t ‘bog’ the fuel in, the turbo comes into play and it will literally pull up the hill without breaking a sweat.

All this happened the week of the FCS weekend so still not actually road tested the thing for more than a couple of miles. Went ahead and fitted (well lashed up) my gauges. Only cheapies that I have had for a while from previous car’s seem to work ok though.



Fitted all the interior in and drove around Exeter, filled up with fuel and drove the long way home. 20 miles on the engine now so I hoped that would be enough as FCS was only a couple days away and still had a few things to sort out.

The morning before we left Darren rolled up and made finer adjustments to the pump, we’re not 100% happy with it due to the air restriction but we wanted it drivable for the trip and not running defiltered.



I hadn’t even washed the car so managed to talk Darren round to doing it while I got bits and pieces together.



And waiting for a few others from the Exeter area to travel up with.



Parked next to James’s ZX



The car did the trip perfectly, no problems and was a pleasant drive. Back home with another Derv mafia coaling machine - the V6 Audi Bus



Pretty much to where the car is at, at the moment. Few little changes to be made, so will update as necessary.

Future plans are:
To sort that awful inlet
Drop the rear a little
Move the intercooler behind the grill for more flow
Build a bigger exhaust
Sort the Driver’s side window
General tidying

The Xantia engine that came out has plans for a rebuild with bigger rods, maybe a bit of porting, and a 10mm pump. The 11mm is a little over kill as it will coal to buggery if you're not considerate. This will be a long term thing as I have other things that need to be worked on first.

Comments always welcome.

Thanks for reading.