205 DTI

[Paul_13]

Pulled the pin out with a bit of heat and mole grips

Cold side is clocked, now for hot side

[Paul_13]

Tried to turn the boost take off and it snapped
so ended up just using the new chra in the old housing, triple checked everything when together properly instead of rushing it like last time.



All back together, just got to sort out wastegate and oil return

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A fair amount of oil came out :/

[Paul_13]

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Much happier with that actuator setup than the last bodge!

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[Paul_13]

Box on with quaiffe in

Just to do -

Timing belt
water pump
Oil drain gasket on the turbo
Fit turbo
Swap tank
Swap fuel lines
make up wiring loom

Start it!

[Paul_13]

It's insured! Gives me even more incentive to get it done

[Paul_13]

Turbo on! I cleaned everything up shop there's no leakage this time. The adapter plate was painted black and some had come off making it smoke in the engine bay

timed up the engine and took the belt and water pump off. Pulleys felt fine, just waiting for replacements in the post

[Paul_13]

One option

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Obviously need the pulley but I think the alt is going to foul the rad.

Other option is the bracket where the PAS is on the sump pretty much but I need a steel sump

[mr_fish]

could you cut/grind down the AC brackets for the other mount to clear?

[Paul_13]

It leaves the metal around the long m7 bolts a bit weak and I've had hair line cracks from doing the same on 6 sumps before

[Danny Wideboy]

I have a spare steel sump for an xud. Needs paint if you are that way inclined, or just a rub up with a wire brush if you aren't.
I'm in Bucks, between Wycombe / Hemel.

[Paul_13]

I'll be up that way at the weekend funnily enough

[Danny Wideboy]

I thought so.
Pm me for details if you want to grab it on your mission.
I have an HDI engine here as well, you are welcome to anything you want from it bar the starter, alternator and conrods.

[Piggy]

Got a diff for this? How did I miss that!

Everyone fitting epic diffs.....dang

[Paul_13]

Bollocks forgot about the sump... You willing to post?

I need the metal intake pipe from around the back of the engine as well.

Well a bit of a set back today, went to rebuild the beam and the quality of the Polish bearing kits is awful, shafts look ok, the bearings were unbranded. One side has play, the other is notchy... Great

Got the engine crane so I'll be dropping the engine in probably next weekend If we don't have any more hospital scares. Work out a bracket setup to retain the PAS and away we go

[Poodle]

Don't know how i've been missing these updates, looking good!

[zx_volcane]

Great progress on this Paul, not much to go then before its dropped in and on the rd!

[Paul_13]

A bit of spare time and a welder lol

[Paul_13]

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Dammit!

[Paul_13]

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This aux bracket puts it too fast forward

[Paul_13]

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That's not going to work either.....
Either gearbox mounted vac pump and PAS pump or saxo pump....

[allye]

Take man pills Paul, get the grinder out.

[Paul_13]

Don't worry about the pills
I don't want to cut anything as in the future I want to convert it back to petrol 8v

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Future investment kind of thing

[Poodle]

Don't the petrol XUs have a pump inlet that points forwards? With where you've mounted it that should give space pointing straight down behind the rad.

[Paul_13]

That is a petrol xu pas pump its off a 6 with the elbow heated up and spun round to face the PAS reservoir (where it was located.
Only problem is the rad is dropped literally where that pump is on a bracket

[Paul_13]

I've just put the rad in as a test and I'm going to have to revert to 1.8 na aux setup and go for a saxo pas pump setup. There's no bloody room!

[welshpug]

you think you have no room with a 1.9 8v try the v6

[allye]

Or a rotrex in a 205!

[Stef205]

Or a rotrex in a 205!

cute!

[Paul_13]

Right rebuilt the beam with the sasics bearing kit and all is good now, good of neat autos to sort that out so fast!

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One job I hate.

I might just send these back to neat autos lol

[Poodle]

Ah i see, that's no help then lol, shame.