Engine Swap- Diesel Turbo 1.9

[calvinhorse 870]

I'm planning a 1.9 dt conversion into my tu engined base model..

 

I've done a search and found a few projects running this engine however they don't really show the ins and outs of the conversion.

 

My shell has the gti style top engine mount but base model everything else, I understand that I will need the diesel gearbox and diesel/gti driveshafts

 

What about exhaust, fuel tank? Does it need a return? Or can I use the single outlet tu tank?

Do I need a lift pump or is it just the mechanical one mounted to the engine?

 

Basically if anyone knows of a how too guide I'd be very grateful, I need a list of pasts so I can gather everything up and get it done in a weekend (long weekend)

 

Thanks

 

 

[welshpug 1,657]

No lift pump but does use two lines, td 205 exhaust required.

 

Either move the gear quadrant post or fit gti subframe.

 

1.6/diesel shafts, or fit 1.9 stuff.

 

Diesel rad, same exp tank as gti, half hoses same as well.

 

205 alternator bracket, 205 alternator, adjuster bracket, no room for crank driven pas, and the 1.9 engine uses a cam driven vacuum pump

 

Probably easier to convert an already diesel 205 or a gti!

[calvinhorse 870]

So can I just swap the inlet outlet part of the fuel tank or is it better to swap to diesel tank?

 

Do I need to use the double thickness diesel rad or will a gti rad be ok?

 

Does the 1.8dt exhaust fit straight on then? Turbo back?

 

[calvinhorse 870]

Thank btw!!

[Tom Fenton 1,542]

Would it not be cheaper/easier to look out for a cheap 205 STDT or DTurbo? I've been there and done this to a 306 a number of years ago, back then I thought it would be a cheap option to do a conversion but in hindsight it cost me nearly as much, had all the ball ache of swapping and making things fit, and then the hassle of insuring it every year as modified. I would have been better off saving up for a couple of months and just buying the car I wanted.

[welshpug 1,657]

Yep 205 dt exhaust, couldnt comment if a gti rad will work ok, the n-a i converted had a twinfan and thick rad as original equipment!

[calvinhorse 870]

Well Tom..

 

Basically for me if I can steadily gather up the bits it's like having finance, bits here and there as and when I can afford them.

 

Also I like to put things together myself so I can see how it works and if there is a bodge I did it myself rather than finding other peoples

 

Plus finding a White 3 door dt isn't going to be easy and I know my car well enough to make the conversion worthwhile.

 

I do fully get what you're saying tho Tom

[Tom Fenton 1,542]

http://www.ebay.co.uk/itm/1991-PEUGEOT-205-DIESEL-TURBO-SILVER-/271061084400?pt=Automobiles_UK&hash=item3f1c7fe8f0

 

Plus

 

http://www.ebay.co.uk/itm/MERCEDES-ARCTIC-WHITE-2K-5L-GLOSS-PAINT-DEAL-HIGH-SOLIDS-2-5L-ACTIVATOR-FAST-/170880749147?pt=UK_Body_Shop_Supplies_Paint&hash=item27c9494e5b

 

Job done?

[calvinhorse 870]

Hahaha! Nice touch with the paint

[welshpug 1,657]

haha, yeah and drop the 1.9 lump in, job done

[allanallen 528 2 Cars]

Edited

 

http://www.ebay.co.uk/itm/1991-PEUGEOT-205-DIESEL-TURBO-SILVER-/271061084400?pt=Automobiles_UK&hash=item3f1c7fe8f0

 

Plus

 

http://www.ebay.co.uk/itm/MERCEDES-ARCTIC-WHITE-2K-5L-GLOSS-PAINT-DEAL-HIGH-SOLIDS-2-5L-ACTIVATOR-FAST-/170880749147?pt=UK_Body_Shop_Supplies_Paint&hash=item27c9494e5b

 

Plus

 

http://www.ebay.co.uk/itm/10-Piece-Roller-Tray-Set-Paint-Brush-Set-Mini-roller-Paint-Roller-Pack-Rollers-/220877489133?pt=UK_DIY_Material_Paint_Varnish_MJ&hash=item336d5303ed&_uhb=1#ht_1382wt_702

 

Job done?

[calvinhorse 870]

Few more questions..

 

Will 1.6 driveshafts fit in a 306 diesel box? Do I need to swap the diff?

 

Will a heavy duty petrol clutch be ok in a diesel?

 

Do I use the 306 top engine mount?

 

If my fuel pump is immobilised I there a way of bypassing this?

 

 

[welshpug 1,657]

Yes+yes.

 

Yes, last diesel engine conversion I did (XUD7 to XUD9TE) I used a stock 1.9 Mi clutch + the original BE1 box.

 

Yes (the arm, not the bush, arm is the same as the 205)

 

Yes, depends which pump you have, but you need to get an ignition switched live to the solenoid, usually entails removing bolts or cutting away steel covers.

[calvinhorse 870]

Welshpug I love you

[Strictly_Derv 34]

I used a 306 DT clutch on mine but it started to slip with the larger turbo so I went for a ceramic paddle clutch. I don't know how the Mi clutch will handle if your going more than a stage 1 tune but I wouldn't personally go for one I'd go for a 306 DT pull clutch.

The GTI rad will be fine too, I've got one with a slimline fan on the inner side of the rad and the original cowling removed so it gets excellent air flow, doesn't really go much above half when giving some 25+ psi boost.

I'd recommend not using the standard top mount IC as I've seen people use it on 205's and there bugger all air flow going up there so your better off getting a small FMIC.

[calvinhorse 870]

Cheers strictly_derv

 

To be honest it won't be getting tuned it's just gonna be a daily!

 

Do the diesels have a bulkhead mounted header tank or is it a radiator type header tank?

 

[welshpug 1,657]

bulkhead

[calvinhorse 870]

Brilliant!

 

Welshpug I owe you a beer

[Josh_Quant 27]

Lucas pump- no need for any cutting to get to the stop solenoid just find the right wire through the plug then give a ignition switch live. (thats what i done)

Bosch pump- i don't know..

Edited January 13, 2013 by Josh_Quant

[calvinhorse 870]

Cheers Josh

 

 

[jamie_1992 66 1 Cars]

give it a week and you'll want to tune it up lol then once you do that you will be addicted

Cheers strictly_derv

To be honest it won't be getting tuned it's just gonna be a daily!

Do the diesels have a bulkhead mounted header tank or is it a radiator type header tank?

[Strictly_Derv 34]

give it a week and you'll want to tune it up lol then once you do that you will be addicted

True that! You will keep going till the standard turbo limits the pump and then till the pump limits the big turbo then will come to an end when your pushing 190bhp and a rods makes a bid for freedom.

I really love these engine, 55mpg, can run on veg and pulls like a train from a £100 turbo, pushing roughly 170bhp. If it blows it's £100 for a new lump plus another £80 or so for the other bits and a day or 2's work.

Once you touch that fuel screw you will be hooked

[calvinhorse 870]

How similar is this block to an xu10 iron block?

Would an s16 alternator mount and lower engine mount fit? It looks like it would?

[jamie_1992 66 1 Cars]

True that! You will keep going till the standard turbo limits the pump and then till the pump limits the big turbo then will come to an end when your pushing 190bhp and a rods makes a bid for freedom.

I really love these engine, 55mpg, can run on veg and pulls like a train from a £100 turbo, pushing roughly 170bhp. If it blows it's £100 for a new lump plus another £80 or so for the other bits and a day or 2's work.

Once you touch that fuel screw you will be hooked

 

what turbo do you run?

[Strictly_Derv 34]

An Audi TT K04 turbo. Soon to be running a GT2559v though