Peugeot Partner 2.0HDI 90 | Intercooler | Boostontroller | Gauge

[4Ward-Performance]

Hi guys!

I'm building as a Project Car for my Workshop a Peugeot Partner 2.0 HDI 90 with Siemens Engine Managment.
I don't want the power limited to a Stage 1 Map.
You guys may know better than I do:
- what Intercooler fits best? (does not matter if I have to cut frontbumper)
- what piping hoses do I need
- what inlet manifold should I you (HDI 107HP?) Does anyone have original spareparts numbers?
- what boostcontroller should I buy and what boost gauge? (I only find rediculous cheap parts or extremly expensive parts

If anyone wants to buy intercoolerpackage - let me know!

I'm aiming for around 160-180hp / 350-400NM

If you want to see me talking about the Project look here - It's in german language!!
https://www.youtube.com/watch?v=a5hadkkl_-A&t=14s

So far I did some repair and service so far:
- Timing and alternator belt
- Frontbreaks
- Frontsuspension (everything)
- Oil and all Filters
- repressed 35mm H&R Springs on Peugeot 306 shortend Sportshockabsorbers

- more to come!!

Regards from Germany
Sebastian
(4Ward-Performance)

[toseland]

Someone will likely come along and whine about this post but the HDi is not as prescriptive as say the VW 2,0TDi movement (they tend to have X turbo, with Y intercooler and Z piping)

Find something that Fits,  and use that as there is LOADS of room in  and around the front bumper, but you will likely need slim line fans. SPAL make nice cooling fans.

Hoses, silicon and alloy i purchased from http://www.autosiliconehoses.com/ Cheap and nice quality.

as to configurations for the intercooler,  Twinpass with both hoses coming through what would be your drivers side is slightly easier, as there is more of a gap on the gearbox side of the vehicle, or a single pass and run a pipe back across the top is also common, there doesnt seem to be a particular type that people use, as big as you want (there are some as large as the radiator itself on here for some of the builds)

You are more flexible with the positioning of the cold air inlet to the turbo as the M/C is on the other side of the car.  if you have a look at my project thread you will see the cold air feed from the air filter comes across the front of the engine and then down under my master cylinder (drivers side, your passanger) into the turbo, and the high pressure from the turbo came out of the top of the turbo, along the back of the engine and across the gearbox.

Ideally you will need the inlet elbow from a 110HDi to deal with the Cold side into the inlet, this is the simplest to way to get the intercooler piping in, the inlet manifold itself is the same but the elbow bolts on

this picture has one with the EGR port cut off and welded (you should remove the EGR)- this one is from this forum   Speak with Poodle or Jonny on here as they sell blanked ones for reasonable prices



As for a boost controller,   http://www.ebay.co.uk/itm/like/220537042109 is a good shout, i have one of these and it does the trick nicely..

Gauges,  obviously TIM turbo and Stack etc are good, pricey but good quality,  but its really uip to preference and how much you want to spend.


With regards to turbos, again it depends on how much you want out of it,  150 is comfortable with good intercooling on a standard turbo (if pushing it a little)  but it runs out of puff around 3500rpm,    GT20 series is a good upgrade for, GT2056s seems to be a common choice,  IHI RHF4 and RHF5 seem to be popping up as well (i had the RHF5 and my next adventure will be with a garrett GTB VNT turbo), so its up to you to find one that suits your needs, bearing in mind there isnt a huge amount of space behind the block so a relocation to the top of the gearbox and associated work would be needed (not sure how that would work out with the Master cylinder the other side on a european vehicle)

with a standard turbo the clutch may struggle with torque at higher BHPs  mine slipped in 5th and 4th at 174bhp.

the exhaust was a limitation on mine as well even though it was decat, i upgraded to a 2.5inch straight through made it lovely to get the power through with little restriction but for 170bhp max i feel a 2.25inch very free flowing exhaust would be adequate. The power was there on mine but the spool was MUCH better with the larger exhaust.

i had wanted to go higher BHP wise but the restriction on mine was the pump (OEM R65) and the rail pressure sensor,   upgrades to these are an R70 (bosch part number 0445010021 ) from a 2.2HDi (its a straight swap) and an 1800bar rail sensor from the 1.6hdi 



If you need a map for the engine management, then speak with HDi-tuning.co.uk as he did mine and i was VERY pleased with the price and results,  other people will also be able to recommend other mappers.

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I would suggest that with the increase BHP you look into a nice break upgrade, the GTi-6 (i think its the S16 on the continent) has larger rotors (283mm) and calipers with a much larger piston. you have a wider range of brake pads and can get the renault clio pads to fit nicely meaning they are cheaper than quality pads for the 266.

the rear brakes are suitable as they are all very very similar in size, only one version of the GTi-6 had larger rear pistons (if i am correct in my reading) but it was tiny and would make very little difference to the car overall so not really worth it

[4Ward-Performance]

Thanks Toseland for your answers!! I didn't expect so many details!
I'll have a look on your progress thread!

I don't wanted to sound dumb. I just don't like to walk in the dark, when someone has done the job and can tell what might fit best  - and what does not.

Do you realy think the R70 fuel pump and pressure sensor from 1.6 HDI will fit? I'm running Siemens ECU and not the Bosch Version.
I guessed that the clutch might be a Problem :-) I can fit a upgraded one if it slips.

As I said, I have a Shop myself and I know HDi-tuning.co.uk very well. I've mapped all of my customers peugeot cars equiped with ECUs he supports with his Software! Even DPF and EGR removes work amazing! I've done many many HDI 90, 107, 133 with him! NEVER had a problem with his work!

[toseland]

Itll be Bosch injection, and seimens ECU i think, so mappable, but i am sure a quick email to steve at hdi tuning will clear that up..

i cant see it being an issue tbh, with the 1800bar sensor and the R70.. They, more than giving you lots of power, provide you with a nice overhead so you dont have to stress things..

mine was running 174bhp on standard R65 and 1350bar, and it was on the hairy edge of throwing codes, took steve quite a few adjustments to get it so it didnt just stall lock you out for 10 seconds (but he did it). the pump and rail sensor were the last limiting factor for me before injectors.

[Poodle]

No, it'll be a siemens fuel system if it has siemens management. The siemens stuff is mappable, it's just not as easy as the bosch iirc. Best bet would probably be to talk to Steve directly, he sees an awful lot of these engines come through and would probably be able to give you some good first hand information. The berlingos have a bit more room than the 306 to work with in the engine bay, you might find you can get a decent-sized blower down the back. Where is the turbo flange on the exhaust manifold? We have just finished designing a flange adapter to allow you to fit a landrover GT2052 down the back of the block, could be an easy solution for you and would comfortably see your target power, presuming the ecu/fuel system can do enough to match the increased air. The flange is designed for the 306-style manifold with the offset flange, i can't remember which mani comes on the berlingo engines, but if it's the one that's central it won't fit so well, although it may still work.

[4Ward-Performance]

Yes it has siemens fuel system. ECU can only be mapped BDM not OBD (no Problem for me to open and read write ECU)
https://www.dropbox.com/s/u3h2v0km73wz1rt/ECU1.jpg?dl=0
https://www.dropbox.com/s/rz0dnodagbgivl0/ECU2.jpg?dl=0
https://www.dropbox.com/s/eu9s7xraazmxov7/ECU3.jpg?dl=0

Turbocharger: (ServiceBox)
https://www.dropbox.com/s/uatdzkpfge2fya...r.png?dl=0

Turbomanifold: (ServiceBox)
https://www.dropbox.com/s/boh3cvb2a9n2hh...d.png?dl=0

But I think these chemes from ServiceBox don't give enough information. I'll have a look what's really fitted when I'm working next time on the car.

You can see a picture of Front suspension here:
https://www.dropbox.com/s/d15fjtjbcmvihi...n.jpg?dl=0

Small Video of the Car rolling
https://www.dropbox.com/s/qvlmehywcrusep...r.mp4?dl=0

Small Video of the New rims
https://www.dropbox.com/s/m6nry8az0t28gx5/rims.mp4?dl=0

[pro_steve]

I've done lots of playing around with the sid801 system.

So to start you can't use bdm, you want a genuine mpps through the obd, or a clone fgtech v54 should do the job. Any cloned mpps tool will wipe the ecu.

I had my van running 155 bhp with the stock turbo, it went really well.
I've done remote maps for people with a turbo upgrade but anything past 160 to 165 bhp and the fuel pump can't keep up.
As the software for these is so complex you can't remove the cut off feature like you can on the bosch edc15 etc.

In my opinion it's best to just go for a heavy stage 2 with my larger turbo outlet and down pipe that made quite a difference and then a nice 2.5 inch system.

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And poodle, Good work. I was going to do this because so many people ask me, looks like you've got it covered though!