1.8 Dt Fmic Guide

[Strictly_Derv 34]

Hi i've decided to put up a guide of how I think would be the easiest/ cheapest option of fitting a FMIC.

I've done it on my old XUD7 TE lump (1.8DT).

It took me about 30mins to fit the parts, but it will take longer on the car.

Be warned, this method ditches the PASunless you want an electric pump from a 106. My daily driver in non-PAS and it's fine even with 185 tyres

So the bits you will need are

• 1.9 DT mani
  
• 1.9 DT vacuum pump
  
• 1.9 DT cam
  
• intercooler and pipes
  

1. Put a jack under the sump with a block of wood and padding and gently lift the engine up so it's not held up by the left upper moun
   
2. remove any bits in the way
   
3. so start off by locking up the engine
   
4. then remove the bracket going over the c/belt to the mount
   
5. pull the engine forward to allow more access to the back to get the mani out
   
6. now start removing the mani 8x allen bolts and 1x 13mm bolt
   
7. use a hinged ratchet to access the bolt, this will be a PITA to get to on the car
   
8. with the engine locked up, now remove the belt
   
9. right now undo the vac/pas pulley and loosen the cambelt cam pulley bolt
   
10. 
    

Edited February 27, 2012 by Strictly_Derv

[Strictly_Derv 34]

• remove the rocker cover and undo the 6x 12mm bolts. I started from the middle outwards.
  
• now remove the cam pulley and lift out the cam. Here's the 2 together, 1.9 on the left, much flatter lobes on the inlet ones.
  
• now remove the allen key bolt in the head which is normally hidden behind the vac pulley, be careful though as this one rounded. This allows oil to the new vac pump
  
• now fit the 1.9 cam shaft, rocker and re-do the belt (best to change it really)
  
• put on the 1.9 inlet
  
• now fit the 1.9 vac on the end of the cam, ensure the slots line up
  
• check everythings back on properly, plump up the cooler and get heat soak free boostin'
  

 

Please note it doesn't need to be in that order, it's just the way I did it.

 

If there's anything I missed please let me know and I will edit! Hope this helps thought

 

Max.

Edited February 27, 2012 by Strictly_Derv

[m_attt 31 1 Cars]

nice one thanks, do you have any pictures of the rest of the install

[Paul_13 212 1 Cars]

Interesting

Have you done any pump mods yet?

Ryan_stdt had a diesel pump in parts on his table and he was showing me how it worked.

He used the pump head off a landrover (11mm instead of 9mm)

 

What did you do with the EGR hole?

Edited February 27, 2012 by Paul_13

[Strictly_Derv 34]

Don't think so, i'll get some up though. I'm running a 1.9 in mine but it's basially the same.

[Strictly_Derv 34]

Interesting

Have you done any pump mods yet?

Ryan_stdt had a diesel pump in parts on his table and he was showing me how it worked.

He used the pump head off a landrover (11mm instead of 9mm)

 

What did you do with the EGR hole?

 

No not yet, I have a modded gov to fit though. Didn't know a landy had the 11mm, thought it was just transit.

They don't have EGR's on the 1.8 or my particular 1.9.

 

Still keeps up with a 225 bhp Audi TT even when I had the pipe come off the boost compensator lol

Edited February 27, 2012 by Strictly_Derv

[Paul_13 212 1 Cars]

Only a certain landy pump, we had a look around the scrappy. It's basically the same as the Peugeot Bosch pump. There's load of information on pug306.net.

There's different cam plates on different pumps.

 

What intercooler hoses did you use? Generic or off a certain car?

[Strictly_Derv 34]

Just the ones from my old 306 DT, Samco hoses and stainless pipes oh and one volvo hose.

 

Still got these s*itty bucket seats clogging up the spare room...

[dirtdog 4]

You're going to regret posting this up...lol. Here come some questions!

 

Does the diffrent cam make any/much diffrence? And am I right in saying the camseal is the same..'7 or '9, it's just the internals which are diffrent dimensions?

 

What are the pics of..the 9 engine or the 7?

 

I've never actually see around the back of the block(having never had it out)...it looks likes it's going to be a fun job with the engine in the car..and I really don't know if I can be bothered taking it out. It took you 30 minutes? I guess it'll take almost a full day without it removed due to the awkwardness.

 

Any pictures of the piping? How are you running a hose off that inlet for the FM..are you using the conversion thing by the guy on the 306oc site?

 

Is your IC above or below the rad?

 

What size are the pipes and where have you routed them etc?

 

 

I've got a 206 hdi cooler but don''t have the dimensions to hand at the moment....it's a bit awkward but I wanted something a bit diffrent and more oem than the cossies one. Hoping to go above the rad (it won't cover the whole grille area but that doesn't bother me) They run 110bhp I think and i'm only looking for a little tune up so it should be nicely suited.

 

Hopefully the pipes will be SHORT..I have seen some set ups and the length of the pipes and the size of the IC fitted by some people is ridiculous...the mere thought of the lag makes me cringe.

 

Thanks for the upload strictly derv!

[Strictly_Derv 34]

I don't know about the cam TBH all I had done waws make a guide to show roughly how it's done, I just happened to notice the lobe size was larger.

I'm using an inlet adaptor, xsantia mani's are easier TBH.

I run a Forge intercooler above the rad, minimal 2" thick pipe which doesn't have much lag atal compared to my old 306 which had a smaller tuurbo but much loger IC route.

[Josh_Quant 27]

I don't know about the cam TBH all I had done waws make a guide to show roughly how it's done, I just happened to notice the lobe size was larger.

I'm using an inlet adaptor, xsantia mani's are easier TBH.

I run a Forge intercooler above the rad, minimal 2" thick pipe which doesn't have much lag atal compared to my old 306 which had a smaller tuurbo but much loger IC route.

 

When you say inlet adaptor, is this what bolts to where the intercooler normally bolt to?

[dirtdog 4]

When you say inlet adaptor, is this what bolts to where the intercooler normally bolt to?

 

Yes

[Josh_Quant 27]

can you buy these or do you have to get them made up?

[Strictly_Derv 34]

You can get one made up but TBH a xsantia/406 inlet would be much easier.

[BenC 6]

can you buy these or do you have to get them made up?

 

A guy on the club 306 forum called jase16gti fabricates them for the xud9, around £35 last time I looked. I believe they would fit.

 

http://www.club-306.com/topic/9013-fmic-adapters/page__hl__%20intercooler%20%20adaptor__st__180

 

(I'm no friend/relation of his - not making any money out of this little 'plug' but thought it might be useful to others!)

[Josh_Quant 27]

Cheers for the reply im only asking because thinking of swapping the 1.8d with the 1.9 td once i finishing paint the mi16 and back on the road.

 

Yeah i know bit of a down grade

 

£35 seems a bit steep though lol

[dirtdog 4]

it is considering you can get xantia/406 manis for about the same price...

[Uberderv 6]

Apparently the 1.9dt camshaft has a different profile. You could use the shaft from a 90bhp DW10 engine which would be the same as the XUD7t.

[madaxgt 0]

Interesting and good work. I need to rebuild my 1.8dt as it overheated and it now pressurises the coolant! Do the 1.9 heads bolt on the XUD7 block? As i could just buy a 406/xantia head complete with inlet and maybe exh/turbo???

 

I put the reliable 205 dt into retirement to replace it with a 206 1.6 hdi gti what a mistake that was....new turbo etc etc, now it just blew its dual mass flywheel!!! Troublesome little dv6 engines. Great if and I mean IF they work.