engine swap - 2.2 hdi into a 2.0 hdi rapier 406

[s13tompow]

Hello everyone! I don't spose any of you on here know whether theres much difference between the 2.2 hdi engines and the 2.0 hdi engines for a straight swap in my 406? ie is the base of the engine (block and head) the same with just a longer stroke or bigger internals?

Just wondering about plugs/sensors on the 2.0 in comparison to the 2.2 so wether i could use the 2.0 loom on the 2.2 and also engine and gearbox mounts.

If anyone would be able to shed any light on this i would be much appreciated!!

Thanks Tom

[Welly]

The 2.2 capacity may well be gained from a stroker kit in the exisitng 2.0 block but the head is completely different because it's a 16 valve head. The 2.2 also runs a complex particulate filter set up, different turbo and probably all kinds of stuff so you'd most likely need everything from the donor 2.2 including the ECU's, keys, looms, everything (as far as I know).

I think it's generally excepted here that swapping engines of a different type is a long process with little reward

Peugeot only fit stuff if it's really needed (a bit like how the 90bhp HDi has rear drums and no DMF etc) so each car is kind of built around the engine spec. The same would apply to the drive shafts, suspension etc..

[steve_earwig]

Nah, same gearbox so the driveshafts are probably the only thing you won't need to change.

[plod]

Fetch good money, don't those 2.2hdi's?

Remeber Ade ( resident coupe breaker over on the coupe club) asking £950 for one, whilst a V6 was £395 (for comparison)

[Bailes1992]

The Peugeot Boxer if I remember also had a 2.2 HDi engine. The 2.2 HDi in the 406 had 16v. The one in the Boxer is 8v and based on the 2.0 HDi engine. Your best bet then would be getting the 2.2 out of the boxer and its a straight swap! You can even use the 2.0 ECU etc etc.

[steve_earwig]

Nicely spotted there - same camshaft, same head, same gasket set, even some of the alternative piston rings have the same number so I guess it must be a longer stroke. I suppose the only mechanical stumbling block could be the flywheel fitting if it's different. There's a lot less emissions stuff on it though, I presume it'd be a case of swapping everything over, using the 2.0's ecu and getting it mapped for the higher capacity.

[min]

I'm reviving this topic since a friend of mine is evaluating some serious investing in tuning his 2.0DHi-110HP 406 saloon. Though today he drove my remapped 2.2HDI saloon and he was pleasantly impressed. I advised him to go for an engine swap since it will cost, most probably, less than the stuff he wants to put/replace in his engine (hybrid turbo, silicone hoses, new pump and injectors etc).

In order for us to have a clearer image of the whole effort, I summarized below the parts we assumed that need swapping from the donor car (he wants to buy a whole donor car in order to have available all the needed parts):

- engine itself with alternator/AC compressor/servo-steering pump/whole clutch assembly;
- starter;
- engine mounts;
- all engine electrics + ECU & BSI;
- gearbox (the 2.2HDI gearbox has slightly longer final ratio, leading to lower rpm at high speeds);
- radiator/fan (they are different?!);
- whole exhaust;
- etc?...

So, has anyone done the conversion? The main concern is not about 'hardware' but about software, meaning complications after ECU & BSI changes...

Any advice is welcome.
Thanks

[Uberderv]

I believe you can control the 2.2 using the 110hp ECU. You can also get 150+ HP out of the 2.0L fairly easily with a few mods.

[min]

You can also get 150+ HP out of the 2.0L fairly easily with a few mods.

He is targeting 200+ HP which is achievable on the 2.0HDI but with serious investment. For the 2.2HDI though this power is easier to reach and also with better long term reliability (comparing the 2 engines remapped for ~200HP).

I believe you can control the 2.2 using the 110hp ECU.

If this can be done it would simplify significantly the whole project, thanks.