Replacement daily hack!

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Re: Replacement daily hack!

Postby lozz » Sun Jan 27, 2013 8:18 pm

8) ibet it runs better with the egr/pipe work cleaned out,
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Re: Replacement daily hack!

Postby dgt » Mon Jan 28, 2013 10:43 pm

It does! I've been told that the turbo is bigger than the Garrett I took out so should eat the already feeble clutch in no time atall 8)

I can't fiddle with the pump yet due to the tamperproofing :frown:

Alas, the car is insured as of this morning, it's almost good to go :mrgreen:

Still plenty to do, all on the cheap... :supafrisk:
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Re: Replacement daily hack!

Postby lozz » Mon Jan 28, 2013 10:52 pm

Angle grinder will sort the Armour on the pump :supafrisk:
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Re: Replacement daily hack!

Postby dgt » Tue Feb 12, 2013 12:07 am

I'm enjoying my new hack quite a lot 8)

More pictures for talking!

First, it didn't take me very long to be at it again...
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Lack of heat was annoying. Out with another motor
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I had my suspicions that the exhaust was not the best. So I got this one from a Xantia
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I was right
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Yes, they don't interchange
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Oh look, the remains of the old turbo :shock:
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Didn't stop me!
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Back to that later....

For now, I'm using a full straight through. More on that and why later too!
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Next, fuel flap and thermo
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Old one blew away!
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Clothes pegged :cheesy:

Decided to change the rad too as the old one was iffy
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New but dirty rad :evil:
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I tried to fit the Xanti-cooler but it's different! Too short
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New rad in. This was a curse to put in!
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And thermo
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Onto the seats
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And parcel shelf
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For this
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A pet hate
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Solved
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Refitting all
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To the front
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Speakers
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Xantia cat and D8/D9 hybrid exhaust!!! :shock:
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Backbox too
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Then general cleaning
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A lonely dark pic in a car park!
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The straight through in action...


The reason for the straight through? The engine is burning oil at an alarming rate!!! :(

Engine swap scheduled fairly soon :supafrisk:
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Re: Replacement daily hack!

Postby lozz » Tue Feb 12, 2013 1:44 am

That exhaust sounds good mate, :twisted:
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Re: Replacement daily hack!

Postby dgt » Tue Mar 19, 2013 12:30 am

I may update this.... Been an interesting month! :)

First, a decent pic of the front of the car
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Boot mat got the bin
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Better
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Removing the GT15 off the other engine
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The problem
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Full set of wheels at last! Changing tyres
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Newish rubber
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Bought a Transit pump
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Ashwood trim
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Back to those later...

Ripping the engine out
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Taking more bits off the other engine
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The oil leak
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The mess left behind
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Cleaning up...
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Transferring the loom. Old one was butchered in places :(
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Oil switch had to be changed...
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Cleaning up all corrosion
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Pump on
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Swapping flywheels
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Back in
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New o rings needed
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Shafts in
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Oops... Thank goodness for taps! :D
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Hose on...
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....and the high pressure seals let go, my nice new oil all over the yard :evil: back to the car a week later...

Back to the Transit pump
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This will be going onto the 406 :cheesy:
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End of that long week 8)
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Old vs new
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Why it let go
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New pipe
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On the road again :mrgreen: buuuuut.... The waste gate sticks open. Why me :(

New passenger foot trim
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Trying to loosen up the wastegate
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Then the exhaust fell off....
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A pikey bodge for now :wink:
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A random new inhabitant of my car :?:
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Foglights needed attention badly
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New screw needed
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Lack of clock light was annoying me
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Yaaaaay!!!!! :cheesy:
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Upside down vent :lol:
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Just 2 weeks.... Fairly dirty already!
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Toolkit maintainance
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Assembled again. Ashwood trim fitted
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The vent is missing? :supafrisk:
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And finally for now, wheels and washed :D
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Hopefully the next update will be fairly interesting :supafrisk:
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Re: Replacement daily hack!

Postby Bailes1992 » Tue Mar 19, 2013 8:14 am

Boost gauge looks 'Familiar' :supafrisk:

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Re: Replacement daily hack!

Postby dgt » Wed Mar 20, 2013 1:02 am



Wahey! :cheesy:

Where did you run the hose? Trying to avoid using the grommet in the passenger footwell.... Also finding it difficult to find a T piece to suit! :?

Seeing as I am posting, I'll throw up some pics :)

First, latest purchase
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Beside a GT15
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And 4 snow pics....
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I have to figure out how to adapt the turbo to fit...!
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Re: Replacement daily hack!

Postby Bailes1992 » Wed Mar 20, 2013 6:02 pm

Mine went through the gromet in the passengers side unfortunatley.
I bought a long tube to do it and the gauge come with a T-Piece.

Had to fit two inline filters to smooth out the gauge as it would vibrate at idle and would jump up the scale.

I've had a D9 HDi90 remapped to 125bhp and a D9 V6 and I think it's safe to say I prefered my D8 TD all day long!
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Re: Replacement daily hack!

Postby Captain Jack » Wed Mar 20, 2013 7:31 pm

Nice pics and work! You wanna work on my car? :supafrisk:
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2003 - 2008: 1998 Peugeot 406 2.1 TD 110bhp LX Saloon
2008 - 2009: 2004 Honda Accord 2.2 CDTI 136bhp Executive Saloon
2009 - 2013: 2002 Peugeot 406 2.0 HDI 110bhp Executive Saloon
2013 - ????: 2007 Peugeot 407 2.2 HDI 170bhp Executive Saloon (mapped to 213bhp :twisted:)
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Re: Replacement daily hack!

Postby Sonia406 » Sat Mar 23, 2013 12:02 pm

Captain Jack wrote:Nice pics and work! You wanna work on my car? :supafrisk:



I was just about to write the same :oops:

I LOVE the sound of that exhaust.... come sort me one out will you :lol:
Excellent pictures, brilliant work - keep it up :mrgreen:
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Re: Replacement daily hack!

Postby rwb » Sat Mar 23, 2013 12:53 pm

Wow

But please tell me you vacced all that crap out of the inside while you had it in bits :lol:

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Re: Replacement daily hack!

Postby Nikolov » Fri Mar 29, 2013 2:51 pm

Nice work,mate!
I don't understand why you swap those things from the transit pump to yours,and what about the turbo?Will it increase the power or you just swap it? :)
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Re: Replacement daily hack!

Postby dgt » Fri Mar 29, 2013 9:01 pm

Wow cheers for the comments!!! :cheesy:

Bailes1992 wrote:Mine went through the gromet in the passengers side unfortunatley.
I bought a long tube to do it and the gauge come with a T-Piece.

Had to fit two inline filters to smooth out the gauge as it would vibrate at idle and would jump up the scale.

I've had a D9 HDi90 remapped to 125bhp and a D9 V6 and I think it's safe to say I prefered my D8 TD all day long!


Eventually I did a very naughty thing.... :shock: Sort of in the pics below! But it worked :cheesy:

Captain Jack wrote:Nice pics and work! You wanna work on my car? :supafrisk:


Not the first to ask....! :mrgreen:

Sonia406 wrote:
Captain Jack wrote:Nice pics and work! You wanna work on my car? :supafrisk:



I was just about to write the same :oops:

I LOVE the sound of that exhaust.... come sort me one out will you :lol:
Excellent pictures, brilliant work - keep it up :mrgreen:


I must get a better vid of the exhaust, it does sound fairly different to any other 406 on the road yet looks totally standard. Bes of all, almost un-noticeable in the cabin :)

rwb wrote:Wow

But please tell me you vacced all that crap out of the inside while you had it in bits :lol:


It needs another clean inside already....! :oops:

Nikolov wrote:Nice work,mate!
I don't understand why you swap those things from the transit pump to yours,and what about the turbo?Will it increase the power or you just swap it? :)


Ah yes, the Transit pump! I need a socket for that....

Basically, the Transit pump distributor head has a larger plunger head and plunger (9mm on the XUD as opposed to 11mm on the Transit) which means that more fuel can be forced through the delivery lines to the injectors. This I'd recommend if using a bigger turbo as with a stock turbo it's a bit pointless...

It does put extra stress on the pumps driveshaft so I'm going to have to be careful with this setup!

Basically this entire part (not just the circled piece):
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Picture from here

I'll do a mini update.... :wink:

Still prepping the car and turbo at the mo. Currently awaiting on a set of circlip pliers!

Turbo stuff
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Needed cleaning
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Clocking was all wrong, compressor housing needs clocking too
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Wastegate valve adjusted round the right way...
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To the boost guage :cheesy:
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Handy hook :P
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Wiring
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Almost right!
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Sealing where I ran the tubing....
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While I was at it, changed the replaced fuses for originals
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Not the cleanest...
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A fuel filter changed...
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Oh dear.... 5k miles....
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I haven't a clue what this is...
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Plenty left to do yet....! :cheesy:
Last edited by dgt on Sat Mar 30, 2013 12:33 am, edited 1 time in total.
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Re: Replacement daily hack!

Postby GingerMagic » Fri Mar 29, 2013 9:26 pm

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.
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Sadly sold the 406, best cars I have ever owned
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