Replacement daily hack!

Post pictures here! Host them in the gallery or at another online hosting site like photobucket.com
User avatar
dgt
1.8 16v
Posts: 97
Joined: Sun May 13, 2012 3:11 pm
Location: Rolling coal...

Re: Replacement daily hack!

Post by dgt » Sat Apr 06, 2013 1:08 am

GingerMagic wrote:Well done fella, great work and great pictures.
I have learnt more about engines looking through your thread than anywhere else..!! You are doing the things I want to do but have no idea - but at least I can see how things work.
Keep it up - can't wait to see the next chapter.
Cheers! I'm glad to hear my posts are some use :)

I guess here is the next chapter...!

Decided to pull my finger out of my ar.... mchair and get this pump built :cheesy:

First: Convenient DXH on a pallet
Image

11mm bolt missing.... :?:
Image

Puller needed
Image

These Polo driveshaft bolts are the right size, length and have collar for locking the sprockets. Stronger too
Image

Slack...
Image

That was a pig to take off.... Thankfully I didn't lose the woodruff key!
Image
Image

Prep for removal
Image

Off! Tamperproof, boooooo-earns :evil:
Image

Yeah right :P
Image
Image

I've removed the throttle assembly, max rpm and idle screw to access the 4 top bolts properly
Image

The 414 vs the 494. The 414 has much cleaner internals
Image
Image

Gov assembly's compared
Image
Image

The mutant result
Image

Next: the head
Image

The head off
Image

The 11mm plunger vs the 9mm!
Image

And distributor heads
Image

All this effort for those bits :oops:

I decided to install it this way
Image

New O ring
Image

All ready to tighten down
Image

Distributor valves
Image
Image

Somewhat finished... The bottom half is anyway
Image

New top seal
Image

Throttle shaft seal
Image

A fiddly job...
Image

I set my pump from full throttle :cheesy:
Image
Image

Finished!
Image
Image

The next day...

Needed cleaning
Image
Image

Better :cheesy:
Image

Back onto the engine
Image

Re-timing
Image

A lack of grease was rectified
Image

I couldn't find a bung so I had to put on a GT15. Still an arse to put on despite being on a pallet!
Image

Cabling up...
Image

So does it work?


Sweeeeeet :mrgreen:

Decided to clean my car too :D

But first, I'll need to find some way to fit this!
Image

After I cleaned the car, I cleaned the glass
Image

Then broke out some polish
Image
Image

Halfway there...
Image

Mirror :shock:
Image

I ran out of light thus need daylight photos... The last thing I did was replace a blown foglight
Image

Plenty left to do....! 8)

As a bonus, I found this vid with the old engine in it... :cheesy:
Image

User avatar
jonsowman
3.0 24v
Posts: 1707
Joined: Wed Sep 21, 2011 4:19 pm
Location: Surrey, UK (J9 M25)

Re: Replacement daily hack!

Post by jonsowman » Sat Apr 06, 2013 8:22 am

Talk about making it look effortless! Well done, great stuff. I enjoy reading your threads 8)
Image
2002 V6 SE Coupé (210bhp) - (Aegean Blue)
2002 D9 2.2 HDi Exec Estate - Samarkand Blue
PM me for PP2000 diagnostics around Surrey

User avatar
dgt
1.8 16v
Posts: 97
Joined: Sun May 13, 2012 3:11 pm
Location: Rolling coal...

Re: Replacement daily hack!

Post by dgt » Thu Jun 13, 2013 2:21 pm

Cheers! I enjoy doing this stuff, more than happy to share! :)

Been long overdue.... But an update!

Not much happened in between as I'm bogged down with college and other projects.... Alas, summer and plenty of time :)

So I'll start off where I left off: A shiny car :cheesy:
Image
Image

Of course I wasn't happy with that so it got a full work over later that week :)
Image
Image
Image
Image
Image
Image
Image

Looked well at night!
Image

Service time...
Image

While I was doing that I decided to change my boot trim and whack a dent out!
Image
Image
Image
Image

Much happier with the pocket :cheesy:
Image

Then some suspension altering occurred....
Image
Image
Image

Quote fed up of my cracked tail light so I replaced it with a new one :)
Image
Image
Image
Image

The leveller broke one night..... :?:
Image
Image

Eh.... Yeah! :?
Image

For the crack I tried the projector lights.... Thoughts?
Image
Image
Image

And had to change my front tyres with a quick wheel refurb!
Image
Image
Image
Image
Image

Before and after!
Image

Image

A quick camber adjustment.... Before
Image

After
Image

So as it stands!
Image

As for the turbo.... How could I forget that! :wink:
Image
Image
Image
Image
Image
Image
Image

Beside a GT15 8)
Image

And on you go! :cheesy:
Image

Still plenty to do..... :shock: :wink:
Image

User avatar
dgt
1.8 16v
Posts: 97
Joined: Sun May 13, 2012 3:11 pm
Location: Rolling coal...

Re: Replacement daily hack!

Post by dgt » Sun Jun 30, 2013 3:37 am

With a few issues to address with the TB25, not much more I can do for the mo....

Plenty of driving about though. With 20psi of boost and a Transit spring in for a gov the power is there when I need it.... It'll do for now :cheesy:
Image
Image
Image




Quite rapid as is :wink:
Image

User avatar
dgt
1.8 16v
Posts: 97
Joined: Sun May 13, 2012 3:11 pm
Location: Rolling coal...

Re: Replacement daily hack!

Post by dgt » Sun Jul 07, 2013 1:29 am

I learned how to work picasa somewhat better! :cheesy:

Fuel filters don't last long here due to the washed diesel epidemic
Image

5k Miles :shock:
Image

Exhaust boo-boo
Image
Image

It'll do for now....
Image
Image

I got a D9 console as I as pestered with botles flopping about everywhere :evil:
Image
Image

Quite.... Dusty
Image
Image

3 completely different cig lighters....
Image

Yaaaay! 8)
Image

Only thing left was the big gaping hole to fill.... So I made up a filler :D
Image
Image
Image
Image
Image
Image

Fluid change was a must
Image

Bulb change as I couldn't see the miles for a while!
Image

Wind deflectors are a must :cheesy:
Image
Image

As for my turbo swap project, I couldn't justify spending more time on it so I gave up....... :cry:


















......And got a bigger turbo instead :shock:
Image

Beside a GT15
Image
Image

Beside a similar sized turbo as the TB2509! :shock:
Image

I didn't hang around
Image
Image
Image
Image
Image

And again beside the GT15, on an XUD mani, correctly clocked :cheesy:
Image

Just the oil drain pipe, wastgate sampler and downpipe to worry about, apart from a bit of adapting the rest was almost bolt on :cheesy:

With the pace the turbo is going at the engine should be in soon :wink:
Image

dirtydirtydiesel
3.0 24v
Posts: 1246
Joined: Sun Apr 28, 2013 11:02 pm
Location: Coalville, Leics.

Re: Replacement daily hack!

Post by dirtydirtydiesel » Sun Jul 07, 2013 9:36 pm

Have been following this thread with great interest, it's looking good 8)
Can't wait to see how it performs :twisted:
2002 110 HDi estate, Rapier in monaco blue! ( found quite a bit more power :cheesy: )
1999 3.0 V6 SE coupe in Diablo Red ( my baby )
2006 206 1.4 16v sport in Aegean blue ( wife's shopping trolley :roll: )

pp2000 owner / user, can offer Diagnostic's / fault code, reading / clearing for beer tokens in Leicestershire.

User avatar
dgt
1.8 16v
Posts: 97
Joined: Sun May 13, 2012 3:11 pm
Location: Rolling coal...

Re: Replacement daily hack!

Post by dgt » Tue Jul 23, 2013 12:34 am

And the saga continues.... :wink:

First, Irish laundered diesel problem in a nutshell. Off with the sender
Image

Traditional ring too big for hole :evil:
Image
Image

Oh dear
Image
Image
Image

Back to the turbo :cheesy: after a lot of experimenting with pipes I found that a shortened thermostat/ heater pipe from a Fiesta on a modified Merc oil return pipe works as a return :cheesy:
Image
Image

Box off reveals this beatuy
Image

Newish glow plugs
Image

Original thermostat. For shame!!!
Image

Cleaning the fuel heater
Image

Polishing the LDA hat to a millimetre of its life :P
Image

And rocker cover
Image

Swapping all the little bits and bobs.... Xantia to 406, a lot of differences!
Image
Image
Image

The standard pipe fits with a bit of manipulation
Image
Image

Sadly, not a hope!!! :(
Image

So out with the consaw and a slab of steel
Image

Drilling to fit
Image

And this was timing to perfection.... This happened as I almost had the engine ready!


Sigh....
Image
Image

Onwards and upwards :D Pump fun.... Swapping dynamic advance shims to Transit ones :cheesy:
Image
Image

Next, wastegate woes..... Finding a way around it was fun 8)
Image
Image
Image
Image
Image
Image
Image

A very crude EGR blank
Image

30k mile clutch..... It's 3rd flywheel :cheesy:
Image

Refurbd pump top
Image

Later that evening....
Image

Next day
Image

But..... Does it work?


Oh yes 8)

Still needs adjustment, downpipe now fouls the linkage but I'll get around that :)

Looking foreward to a test drive when I have it set up the way I want it! :cheesy:
Image

dirtydirtydiesel
3.0 24v
Posts: 1246
Joined: Sun Apr 28, 2013 11:02 pm
Location: Coalville, Leics.

Re: Replacement daily hack!

Post by dirtydirtydiesel » Tue Jul 23, 2013 9:10 pm

Looking good dude, the effort you put in is mega, are you going to plumb in a intercooler cos you'll need it with th boost temp's that bad boy could run :twisted:
2002 110 HDi estate, Rapier in monaco blue! ( found quite a bit more power :cheesy: )
1999 3.0 V6 SE coupe in Diablo Red ( my baby )
2006 206 1.4 16v sport in Aegean blue ( wife's shopping trolley :roll: )

pp2000 owner / user, can offer Diagnostic's / fault code, reading / clearing for beer tokens in Leicestershire.

User avatar
dgt
1.8 16v
Posts: 97
Joined: Sun May 13, 2012 3:11 pm
Location: Rolling coal...

Re: Replacement daily hack!

Post by dgt » Fri Jul 26, 2013 1:39 am

dirtydirtydiesel wrote:Looking good dude, the effort you put in is mega, are you going to plumb in a intercooler cos you'll need it with th boost temp's that bad boy could run :twisted:
Cheers! They come with an intercooler as standard, was looking to fit one from an Iveco but it's huge :shock: Something else might crop up though!

More of a how I solved it rather than an update but it may help someone in asimilar situation :cheesy:

After getting it running, it wasn't going right.... Time to adjust this pump!

LDA adjustment (star wheel + smoke screw)
Image

Relocating the linkage for a shorter throw. Also adjusted the position of the arm on the splines
Image

Adjusted the fuel screw. Stubbys are handy for such small spaces!
Image

Beware screwing out the pump when the car is running, I shorted out the stop solenoid and blew fuse 25 in the main fusebox :?

Much more room to access the exhaust bolts 8)
Image

When all that was done I went for a test drive. All grand until no power atall :?: It was creating a vacuum!!!!

Image

Must be the pipes.... No, all clean.

Must be the cooler
Image
Image

No, it's fine

Must be the wastegate, so I sealed it shut
Image

No. I was going out of my brain :cry:

Then I tried it without a filter..... Success!!!! :cheesy: It's got the bin since :P

So I've been enjoying my car all evening since, just needs further tweaking in places and perfect :cheesy:
Image

User avatar
dgt
1.8 16v
Posts: 97
Joined: Sun May 13, 2012 3:11 pm
Location: Rolling coal...

Re: Replacement daily hack!

Post by dgt » Tue Aug 06, 2013 7:53 pm

It's just more developing for me.... Looking to try and fit a Sofim 2.8 air cleaner infront of the box! :shock:

For now, I've assembled a pipe from a Volvo and 2 Ivecos :P
Image
Image
Image
Image
Image

Brand new tyres
Image

Completed a long run happily enough too 8)
Image
Image

And some vids of the turbo in action :cheesy:

Image

User avatar
dgt
1.8 16v
Posts: 97
Joined: Sun May 13, 2012 3:11 pm
Location: Rolling coal...

Re: Replacement daily hack!

Post by dgt » Sat Dec 28, 2013 9:09 pm

Time I poked my head in here again :cheesy:

As of the 5th of Jan, I'll have this car a year :cheesy:

Since the K14-2 swap, this car is an EPIC daily driver. Very few can outpace it, as a young fella in a WRX found out one night at the lights :cheesy: :cheesy: :cheesy:

Not much has changed, although the car is in a sorry state at the moment :( more on that later...

Apart from that, what have I been up to? Enjoying my car 8) and enjoying the way it goes!!! :cheesy:

I needed a filter, hated running de filtered...
Image
Image

One day on the motorway, I lost all power.... :?:

Back of the car looked like this after cleaning it that morning!
Image

The culprit for my loss of poke
Image

From a Xantia
Image

And back on my way I went :cheesy:

Didn't clean the back of the car for ages after that :lol:
Image

Small exhaust issue....
Image
Image

Only a small issue....
Image
Image

Mock up for correct length
Image

Back on the road again :D Time to enjoy the car 8)
Image
Image
Image
Image
Image
Image

However, I wasn't happy with the way it handled.... And lost diesel :shock:

So I got a small box of parts :)
Image
Image

After the linkage broke in an irritating manner, it was first on the change. Pikey bodged at the side of the road! :lol:
Image
Image

Better :)
Image

Now.... The fuel leak....
Image

Am thinking of fitting these :supafrisk:
Image

Painted the drums when they were off
Image

Out!
Image

Culprit
Image

Cleaned the sender when it was out
Image

Considerable hours later, after much swearing.....
Image

Done! Arb bushes now, note it's feckin dark....
Image

Much needed!
Image

Needed to sort the downpipe
Image

And weld another hanger
Image

Job done! Next day was just configuring the exhaust.... Uh oh :oops:
Image

Can't have that, emergency pikey fix!!!

Take a lump of a Stilo....
Image

Cut it
Image

Shape it
Image

Bend it
Image

Drill it
Image

Now we hack the pipe off
Image

Jam this lump of a coat stand onto the pipe.....
Image

Weld it and a lump of a 106 box onto it....
Image

Rivet the piece from earlier on...
Image

And now we have a handy way of covering up a mess that would have needed a new bumper otherwise :cheesy:
Image

Next was to sort an awful banging from the front.... I was sure it was the stabilizer

So I rooted this one out
Image

Hmmmm....
Image

Out you go!
Image

Oh dear.....! :shock:
Image

Honestly not surprised it went with the power from it :cheesy:

Messy job though
Image

But that cured that :cheesy:

Strengthening the tail pipe hanger
Image
Image

See, coat stand :lol:
Image

Then..... Disaster. Timing belt went :cry: Not overly upset as it was a development engine. But annoying to say the least!

To my inventory, out with a spare head..... No make that a full engine! Head for now :D
Image

Now let the porting madness begin...
Image
Image
Image
Image
Image
Image
Image
Image
Image
Image
Image

Can't wait to have that in the car.... Actually, I can't wait to have my car back full stop, I miss it so much! :cry:

How it currently looks...
Image

But how am I getting about? Well, this is the daily hack for now....
Image

RWD is addictive (I have gone through 4 sets of tyres :shock: ) but it can't hold a candle to the 406 :cheesy:

Also that E39 isn't the blue one from earlier in front of the 406, I have 2 of them. It's a V8 :supafrisk:

What will my next update entail? 8)
Image

User avatar
dgt
1.8 16v
Posts: 97
Joined: Sun May 13, 2012 3:11 pm
Location: Rolling coal...

Re: Replacement daily hack!

Post by dgt » Fri May 16, 2014 8:50 pm

Time I poked my head in again.... :wink:

Lets wind the clock back to March.... I needed my car back and fast. Onwards and upwards!
Image
Image

Getting there....
Image

Pump off
Image
Image
Image
Image

On with the hybrid pump, static advanced
Image

Sump off
Image
Image

I could eat me dinner from that :cheesy:
Image
Image
Image

Many minutes later....
Image
Image
Image
Image

Pistons next
Image
Image

Bin
Image

New!
Image
Image
Image
Image

Need the pulley
Image
Image

W/Pump, rollers etc
Image
Image

Diesel pump work 8)
Image
Image
Image
Image
Image
Image

On with the pump lines again
Image

Cleaned up my cam
Image
Image
Image
Image
Image

Pump on
Image
Image

Injector plumbing
Image

Studs and manifolds
Image
Image
Image

In the car it went 8)

New brakes
Image
Image

A week later, the accelerator cable snapped
Image
Image
Image
Image

So as it stands :cheesy:
Image
Image

Sounds as good as ever too 8)


Image

User avatar
jonsowman
3.0 24v
Posts: 1707
Joined: Wed Sep 21, 2011 4:19 pm
Location: Surrey, UK (J9 M25)

Re: Replacement daily hack!

Post by jonsowman » Sat May 17, 2014 9:44 am

I love reading your threads, fantastic work :cheesy:

You're going to have basically new 406 at this rate!
Image
2002 V6 SE Coupé (210bhp) - (Aegean Blue)
2002 D9 2.2 HDi Exec Estate - Samarkand Blue
PM me for PP2000 diagnostics around Surrey

User avatar
dgt
1.8 16v
Posts: 97
Joined: Sun May 13, 2012 3:11 pm
Location: Rolling coal...

Re: Replacement daily hack!

Post by dgt » Mon Jul 21, 2014 2:07 pm

Cheers! But like all good things, they have to come to an end sometime :cry:

Time I closed the book on my fantastic daily driver

Since the engine was done I covered 4k miles in it in I think 6 weeks.... There was one week I had over 600 miles put up in 2 days, I was looking to blitz well into the 1000 mile week and beyond :shock:
Image

However, on day 3 of that week, I decided to stop driving the car to sort out a small oil leak. Was running it on 5w40, it went through it very fast :oops: the one and only 406 ever to enter my garage to add to the list of legends that have graced those doors over the years 8)
Image
Image

When I had that sorted, I put up the final 200 odd miles with new oil. The juddering was only getting worse and worse The last time I drove it I was merging onto a motorway when I lost all drive, the clutch completely rang I found out after. Not surprised really :lol:

So it had to be brought home on a recovery truck where it stayed at the front of my house for 6 weeks.

The last bit of work I done was to change a tyre on it, then replace the spare with the new wheel and tyre
Image
Image
Image
Image

The later that evening, I waved goodbye to my old friend. Literally heartbreaking to watch it being towed off
Image

I know it's gone to a good place, I know the lad who bought it well, mad into XUD's too. He has it running too! :cheesy:

As for my next car? I can't see myself with another 406, as that one was very special to me and any other one just couldn't cut the mustard compared to it. Although I said that before about Alfas.... :oops: So you never know :wink:

For now, I drive a Mercedes C200. It has a welded diff :cheesy: I serviced it, sorted out a propshaft issue, got some 17's for it and slammed it. It's great for drifting :cheesy:
Image
Image

It's a really nice car but is a stopgap while I source parts for my next sleeper car: an Alfa 156 3.0. Initially I had a strict deadline to get this car running by but with the waiting time for parts and the stress it was causing me, I decided to scrap the deadline, use the Merc instead and build the 156 in my own time :)

Then when up and running I have a turbo to put on it..... :supafrisk:
Image

Should prove to be interesting when up and running!

So that's me done with 406's for now. I'll never forget my 2, for different reasons. But I'll look back with fond memories of this one in years to come :cheesy:
Image

Post Reply