1.8 Dt To 1.9Dt

[Strictly_Derv 34]

I'm going to be doing XUD9 TE conversion with a modded Bosch pump and Forge FMIC to my 205 soon -ish. I know the basics of the job and I know my way round cars but i've never done an engine swap.

 

I'm just after some advise on the swap so I won't be stuck without my car which is my daily driver. I know the engines are pretty similar but a few bits vary as the engine i'm getting is from a 306.

Any pointers would help and also knowing the best way to get the engine and box out would be helpful

Will also be de-EGR'ing it as I have a 405 inlet and outlet manifolds so added bonus

Thanks

[Daviewonder 533 3 Cars]

I can't give you any advice but I do have an engine hoist you can borrow

[Strictly_Derv 34]

That would be handy! Can't believe I didn't think about the hoist

 

I think I'll be getting the powerplant sometime this week so I'll contact you when it arrives

[peter 20]

ive done this a fe times and they go very well!! the way i do it with no hoist (and tbh i think its easier) drop the car on the floor undo engine mount and box then just jack the car up and drag the engine out for underneath.

 

only thing thats a bit different is the water pipes but you'll work it out!

 

as for the front mount ive never done that on a diesel but that will be a bit of a nightmare!

[ryan_stdt 2]

when i did mine i used all the ancillaries off of the xud9 engine.

 

are you going to fmic it straight away as i dont thing the standard tmic will fit under the bonnett. it will be a bit of a bit*h to fit a big IC up front, i went for a smallish fmic off of a bmw E94 i think, and fitted it above the lowered radaitor.

 

which gearbox and shafts are you going to be using?

[Strictly_Derv 34]

peter- do you leave it on the subframe?

 

The FMIC shouldnt be a problem as I've prepared for that

[Strictly_Derv 34]

Ryan what gear box did you use? The 205 one is way too short 3k at 60 in fifth

[Paul_13 212 1 Cars]

I'd go for a HDI box

What Ryan used and work well.

Inner cv is a problem though. You have to swap the diff to a 205 item or the easy way, swap the inner cv cup (if your running 1.9 shafts)

I think the loom is a straight swap, Ryan will confirm this.

 

Big radiator a must, lower it aswell.

I don't we had a problem with the coolant hoses as they swapped from the 1.8t

 

And don't go for aftermarket mounts

[Paul_13 212 1 Cars]

30 psi of boost ftw

[Strictly_Derv 34]

I'd go for a HDI box

What Ryan used and work well.

Inner cv is a problem though. You have to swap the diff to a 205 item or the easy way, swap the inner cv cup (if your running 1.9 shafts)

I think the loom is a straight swap, Ryan will confirm this.

 

Big radiator a must, lower it aswell.

I don't we had a problem with the coolant hoses as they swapped from the 1.8t

 

And don't go for aftermarket mounts

 

 

cant afford one atm but the engine comes with a 306 DT box so can I just swap the diffs over? I have the standard shafts on still

[ryan_stdt 2]

i used the 205 loom and the two temp sensors on the thermostat housing

 

yeah the 205 box is very short, i used a hdi box and 1.9 shafts and changed the inner cv cup.

 

What rad are you using, and which model of 205 is it going in? Dturbo or just a turbo diesel.

 

is that a cosworth cooler?

[Strictly_Derv 34]

thats rads from a TU 205 as my other broke seems to keep it cooler than the other one lol. The cars badges up as a Dturbo and the coolers a Forge item which I had on my old 306 Dturbo

[Paul_13 212 1 Cars]

I'd definately get a STDT rad mate it gets a lot hotter than the 1.8dt engine

[Weser 30]

Just looking through this and wondering if you are still going to keep the powersteering on the 205? I see you have it at the moment but IIRC the powersteering pump on the 306 engine fouls the rad on the 205. Are you going to use an electric pump?

[Paul_13 212 1 Cars]

That will be a prob for the fmic pipework aswell

Edited September 20, 2011 by Paul_13

[welshpug 1,657]

I'd definately get a STDT rad mate it gets a lot hotter than the 1.8dt engine

 

same rad...

[Paul_13 212 1 Cars]

same rad...

 

I know that, he's using a TU rad on his 1.8dt. Why I said use a STDT rad.

[ryan_stdt 2]

Mine seemed fine on the run but did get hot after a few minutes of hard driving, and get very hot in traffic. And that was with a td rad.

 

I forget about the pas pump because I used a manual quick rack.

[Paul_13 212 1 Cars]

One thing I did forget about is tensioning the aux belt, can be a pain!

[Strictly_Derv 34]

^ why's that? Piece of piss on mine. I will be de-PAS'ing my rack as Daviewander uses a de-pas'd one on his 2.0t GTI and he says it isn't too bad so the XUD can't be much heavier TBH

 

So what will be the best method of removing the engine will it be out the top or drop it on the floor? A step by step guide would be much appreciated

[allye 530 3 Cars]

If you have a crane - out the top

If you don't - out the bottom

 

[Strictly_Derv 34]

Hopefully I will have access to a crane so will the bumper need to be off to do this? I've heard about bolts being rusty on bumpers and non re-usable

[welshpug 1,657]

nope, but removing the rad and slam panel will make it a lot easier.

[Strictly_Derv 34]

Ahh thats alright then, had them off countless times! Am I right in theinking the g/box can stay attacked when removing the engine?

[allye 530 3 Cars]

Ahh thats alright then, had them off countless times! Am I right in theinking the g/box can stay attacked when removing the engine?

 

Yer leave it on the engine.