New Build Possible Issues

[wardy18 33 1 Cars]

OK i now have the new XUD9 Iron block fully stripped and cleaned ready to be sent off to QEP.

 

I thought it would be best to get well aquanted with it now as i wont be seeing until the new year and so to prevent unforseen fitment problems, and sure enough i have found a few!!

 

1) The biggest problem is that the oil dipstick is at the front of the engine and runs through what would be the equivalent in a 205 of the oil filler/breather bottle, but this sits right below/infront of right 2 inlet ports so would be in the way of the carbs mani. This means i might have to simply run my normal ally oil catch/breather/filler tank to the filler pipe in the block and simply not run a dipstick on this engine!! There is however on the back of the block a electronic oil level sensor probe which i dont know if you casn maybe buy after dipsticks that i could then utilise this hole otherwise it will simply blocked up. Or i could actually wire it up to a warning light and utilise the probe

 

2) I will need to find out if i need to run a sump spacer or 2 because of the extra long 96mm stroke crank, in this case do i need to lower the level of the oil pump because the pick up would no longer be close to the sump bottom?

 

3) I am unsure from the 205 what the electrical sensor to the right of the oil pressure sensor is, its the large bowl type thing that screws into the block and has one electrical spade connection on, WHAT IS THIS? Im asking because the XUD9 block doesnt seem to have it, it only has the oil pressure sender directly above the filter.

 

4) The XUD9 block had a oil warming/cooling unit in place of the normal 205 oil filter sandwich plate. Obviously i have removed all of this back to the bare block at the moment and would like to keep it this way BUT removing this unit meant removing the large bolt which secured it to the block one end and had the oil filter screwed onto the other so making a complete unit. So with this removed it means there are no threads coming out of the block to screw a filter onto?! Can something be removed from the 205 XU9 block and used on this block??

 

I think thats all for now, would be great if someone has already used this block or very similar and so may have already come across these possible issues?

 

Best Regards

 

Simon

[Bally123 0]

See my comments below, can't help with all your questions but I will watch this thread with interest.

 

Cheers

 

Bally

 

OK i now have the new XUD9 Iron block fully stripped and cleaned ready to be sent off to QEP.

 

I thought it would be best to get well aquanted with it now as i wont be seeing until the new year and so to prevent unforseen fitment problems, and sure enough i have found a few!!

 

1) The biggest problem is that the oil dipstick is at the front of the engine and runs through what would be the equivalent in a 205 of the oil filler/breather bottle, but this sits right below/infront of right 2 inlet ports so would be in the way of the carbs mani. This means i might have to simply run my normal ally oil catch/breather/filler tank to the filler pipe in the block and simply not run a dipstick on this engine!! There is however on the back of the block a electronic oil level sensor probe which i dont know if you casn maybe buy after dipsticks that i could then utilise this hole otherwise it will simply blocked up. Or i could actually wire it up to a warning light and utilise the probe

 

If you wanted to use the probe it cannot be just wired to a light, It would be necesary to build an electronic interface and you need someone who has reasonable electronic skills, its pretty straight forward to do and with some thought it could indicate both level and a low warning light. Alternativley remove it and adapt into a dipstick tube?

 

2) I will need to find out if i need to run a sump spacer or 2 because of the extra long 96mm stroke crank, in this case do i need to lower the level of the oil pump because the pick up would no longer be close to the sump bottom? Can't help you here...

 

3) I am unsure from the 205 what the electrical sensor to the right of the oil pressure sensor is, its the large bowl type thing that screws into the block and has one electrical spade connection on, WHAT IS THIS? Im asking because the XUD9 block doesnt seem to have it, it only has the oil pressure sender directly above the filter.Its an oil presure sensor for the in dash pressure gauge, the other one you describe is more accuratley described as the oil pressure switch

 

4) The XUD9 block had a oil warming/cooling unit in place of the normal 205 oil filter sandwich plate. Obviously i have removed all of this back to the bare block at the moment and would like to keep it this way BUT removing this unit meant removing the large bolt which secured it to the block one end and had the oil filter screwed onto the other so making a complete unit. So with this removed it means there are no threads coming out of the block to screw a filter onto?! Can something be removed from the 205 XU9 block and used on this block?? I'll Pass on this one but a photo might help to clarify things

 

I think thats all for now, would be great if someone has already used this block or very similar and so may have already come across these possible issues?

 

Best Regards

 

Simon

[wardy18 33 1 Cars]

Thanks for the replies mate,

 

I would prefer to adapt it to an oil dipstick, the 205 diptstick seems nothing special as the tube simply slots into the whole in the back of the engine block, doesnt seem to seal at all so this means i could always remove the probe from the threaded nut/bolt and drill a suitable sized whole for the 205 dipstick tube to sit in, will just have to test the depths and once i have the correct amount of oil in. doesnt sound difficult!!

 

Ah ok, so do you actually need both?! I have a oil pressure guage on my little dash unit and also an oil pressure light (which i dont take much notice off as i keep an eye on the oil pressure) so which one does what, all i really need is the oil pressure for my gauge but this XUD9 block only seems to have the Oil Pressure Switch and not the Larger Sensor Unit to the right?! Will the Oil Pressure Switch give me the pressure reading i need on my guage?!

 

Ill get photos on the Oil Cooler unit up tomorrow

 

regards

 

Simon

[Kev-G 1]

4) The XUD9 block had a oil warming/cooling unit in place of the normal 205 oil filter sandwich plate. Obviously i have removed all of this back to the bare block at the moment and would like to keep it this way BUT removing this unit meant removing the large bolt which secured it to the block one end and had the oil filter screwed onto the other so making a complete unit. So with this removed it means there are no threads coming out of the block to screw a filter onto?! Can something be removed from the 205 XU9 block and used on this block??

 

There are 2 different length adaptors which are used dependent upon whether or not you have an oil cooler. I would suspect you are going for an oil/air cooler therefore replace the std. XUD sandwich plate with the appropriate one for your cooler.

[wardy18 33 1 Cars]

I have never run an oil cooler, because im just for Hilclimbing/Sprinting i never saw the need for one as its not getting a constant pouding round a track or antyhing like that!! Not sure if i will need an oil cooler with the new engine. I will have to source the adaptor from an XU9 Ally block so i can run just a filter and no sandwich plate etc.

[omega 82]

just a thought with the oil gauge

the 406 2.1 deisel has a gauge that works when you switch the ignition on [checks level then goes off] and has a dipstick so you might be able to rob some bits of one

[wardy18 33 1 Cars]

This will sort the Oil Filter Thread issue out a treat

 

Ebay Clicky

 

Do i get Forum Discount Mr PugRacing??

Edited October 30, 2009 by wardy18

[wardy18 33 1 Cars]

The T-Piece i need for fitting Oil Pressure Switch and Sender Unit

 

T-Piece

 

I need to buy a kit to work out bolt and thread sizes ie M14 x 1.5mm etc

[wardy18 33 1 Cars]

Been back on the new block and have nicely sorted out a couple of issues.

 

1) I found an old Sump Drain Plug which once cleaned up and given a new copper washer was a perfect blanking plug for a oil way that i dont need

 

2) I now have a Fully functional dipstick, i had another sort of drain plug which fitted perfectly to where the old oil level probe screwed in so i drilled through the plug to allow the std 205 dipstick tube to sit very snugly through, all i need to do now is once i have the 4 ltrs of engine oil in i will adjust the level marks on the dipstick to give me indications of wher the full 4ltr mark is. See pics as follows:

[wardy18 33 1 Cars]

Also now sat on my old head for a mock up to ensure the dipstick securing bolt lines up and miracles with a little adjustment it lines up perfectly!!

 

One thing though which i have always thought to be odd is that the 205 dipstick hole in the block doesnt seem to seal with tube in it, the tube just seems to sit in the hole, i can only assume the hole is far enough up the block that no oil can forced up and out and so the same should apply with my new design (even though my new design on the XUD9 seals much better that the XU9 set up)

[wardy18 33 1 Cars]

Can anyone tell me the Thread Sizes of the Oil Pressure Switch and the Oil Pressure Sender Unit?

 

I can get the T-Piece in M16 x 1.5mm to fit correctly into the block but i can only assume that the threads for the pressure switch and sender will be correct as the listings do not state these?!

 

Demon Tweeks T-Piece

[James_R 3]

Pug Racing does these items aswell so might aswell order the thread stud and T-piece for it too

[wardy18 33 1 Cars]

Ive sent him an email through Ebay for the 2 items earlier so awaiting replies, however his T-Piece is over £3 more than what Demon Tweeks offer which is alot for a little item, ill see what he comes back with

[wardy18 33 1 Cars]

Next issue i have come accross is the Top Engine Mount, the original 205 mount bolted into the head (2 at the front one at the back) and then one large bolt into a top sticking out section of the Ally block which also attaches the Alternator Bracket.

 

Hoever, the XUD9 Iron block doesnt not have this section for this bolt and so the top engine mount will JUST be bolted to the head which i dont really like, always good to have that security bolt in the block.

 

This also causes another issue, my XU9 alternator bracket possible wont have anywhere to bolt to.

 

There are smaller bolt holes on the front of the block which arnt being used so i think i may need to have an ally bracket made up which utilises bolt holes for the alternator and the top engine mount. Anyone know anywhere i can get this done?!

[Sandy 191]

I'd advise making it from steel, less chance of cracking than alloy in this case.

[wardy18 33 1 Cars]

We havent got a decent machine shop over here so im going to have to out source this, any ideas?!