[engine_work] 205 Sdtd - 2.1 12v Turbo Diesel

[weejimmy 1]

Well as said in the other thread ill start a wee 205 works thread for this

so far i have got a 406 2.1 td with electronic lucas pump and fitted a 1.9 td bosh mechanical pump.

it ran in the 406 so it does work,

 

i took engine out 406

and removed the 2.1 box as ill be using a 306 td box

flywheel was rather large / heavy

 

 

so put the 306 1.9 td fly clutch and box on

 

droped it in the 205 but the down pipe rests on the gear linkages and is about 4" up from the exhaust tunnel

 

.

 

the down pipe goes down underneath the turbo so ill need to make one up to go up and over. and round. avoiding gear linkages.

 

had to change the back mount from 2.1 to 205 gti etc

 

apart from that, the clutch fly and box. oh and the top mount, its prety much straight in.

 

ill update as i go

Edited February 18, 2009 by weejimmy

[Cloverleaf 1]

Interesting project...didn't realise a 2.1 was fitted to the 406.

[weejimmy 1]

heres a good pic of the down pipe

as you can see how it goes under turbo so ill need to make a up and over one,

not got any bends just now so need to go pipe shopping soon

 

 

and another

 

Edited February 18, 2009 by weejimmy

[Hilgie 16 2 Cars]

You'd have to remove that part altogether and create a new exhaust from the flange on.

[weejimmy 1]

yes

could either use the old flange and make one from mild or just a whole new one from stainless,

but this is just a budget job so mayby modding the original will do for now.

[Guest ebrett]

Very nice project. Seen this done on a 205 van on youtube. It really flys

 

[weejimmy 1]

ok so its been a while since i updated this basicly because i ran out of gas for welder again and dont want to spend £65 for a small bottel from adams gas again but cant find it anywhere else.

 

also the stdt i was going to put the engine in was a bit rusty on the shell so ive been on the look out for a good one.

was going to go see a stdt in a couple of days but this poped up and ive just bought it.

 

got it lochal to me. 99k on the clock non sunny realy good shell and interior will be ok with a small amount of work.

 

only problem is its a gti and the idel is a bit crap, but the engines coming out anyway to make room for the td.

 

couple of pics inc boot full of spares

 

 

 

 

 

 

so ill wait till i get down pipe made up on the bare shell then take this gti engine (1.9) out and drop it in.

Edited March 27, 2009 by weejimmy

[weejimmy 1]

well sorted idle in the gti engine by pluging in the airflow merter properly.

 

and now have the engine and box out so going to now strip all the gubbins i dont need out the engine bay.

 

 

 

also got the ecu and holder out from under the dash.

blody things held in by the same bolts that hold the dash in so a bit of a job to get it out lol..

but no ecu needed so no point in having it left in.

 

 

 

also got pipes for exhaust and got them lined up and cut to size.

sent away to get welded as still no gas, but i have found somwhere at last and have a new welder orderd aswell.

 

should be back tomorow with more progress

[weejimmy 1]

ok so decided to rip out all the gti wiring,

inc the 2 brown plugs that go int the ecu loom.

WHAT A BLODY JOB THAT WAS!!!! not so much hard to do just mind bogeling.

why dose a wire run from the starter to the fog light???? well not realy but theres loads of wires that conect random plugs.

and me being me decide to strip it all down thinking the lights etc would be on seprate wiring looms to the rest of the looms but its all one piece apart from the window wipers. realy weird.

 

 

had to take dash off and half the fuse box conections out aswell

 

 

 

 

 

 

then put the diesel turbo loom in for the guages etc etc

 

 

fuse box is a bit messy but its all in so ill tidu up once i know its working 100%

 

 

 

exhaust has been tacked up in place so just need to get the flanges on at right angles and we are away with that.

geting there

 

 

still need to re-wrap the engine bay loom now

Edited April 28, 2009 by weejimmy

[weejimmy 1]

well i changed my mind on moding the origanal downpipe so made one up out of 316 stainless. using mandrel bends, As i couldnt get 2.5" tubing to fit i used 2" but that should be fine for the power ill be running. the plan is to get as much power from stock turbo as i can then make a dp style mainifold and run a bigger turbo once i know the stock turbos limits.

took ages to get it all lined up althoe it looks straight forward 90 deg bends it's not.

 

taped it all in place and got a mate to tack it up as im out of gas. cheeres davy

but should have gas to weld it up and weld the flanges on soon.

[sounds of silence 2]

got it running yet a want a shot

[weejimmy 1]

il get mine out if you get yours out.

[sounds of silence 2]

before the weekend ?

[sounds of silence 2]

get the shell prep'd yet

Edited April 30, 2009 by sounds of silence

[weejimmy 1]

you getn the beast on knockhill on sunday??????????

 

na ave no got the shell done yet.

ill get it done soon man,

 

now stop filln ma projet thread up wi junk lol

[Uberderv 6]

Hi WeeJimmy,

 

Is the engine in the bay yet? I was wondering if it is how much clearence is there for the brake master cylinder?

[rapidmi 4]

get the shell prep'd yet

 

get the finger out lol

[weejimmy 1]

Hi WeeJimmy,

 

Is the engine in the bay yet? I was wondering if it is how much clearence is there for the brake master cylinder?

 

 

engine is in a 205 just not the right one.

 

theres plenty clearance on the mc to the engine, its just makes the exaust a bit more tricky. still doable thoe just quite a tight bend,

 

ill get a pic tomorow.

[weejimmy 1]

thot ad update this a bit, but only have a couple of pic on my comp now ill get more up soon

 

heres the 1st down pipe i made up.

 

 

but then after that i decided to go cable shift so i could get a shorter one with less bends on where the old L bracket used to be

[B1ack_Mi16 67]

How's this one proceeding?

 

I wonder if the 1.9 TD pump is working well on the 2.1 engine?

 

I still have big time problems starting my 2.1 in the 405 and now I consider to change the diesel pump for a 1.9 TD one that I know came from a engine that always started bang on and no problems with that at least.

[Dum-Dum 0]

Jimmy this needs an update

[Saveit 0]

Never got finished?

[Liquid_106 97 1 Cars]

Never got finished?

Shame if it didn't, oil burners give me naughty thoughts

[lewthepimp 0]

i think he packed it all in to concentrate on something else