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  1. #1
    Active Member ginge191's Avatar
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    Default XUD9TE engined 205 gearbox mounted turbro (pic heavy)

    Long time no see... and for those that don't know me - hi!

    I'll keep this as short and sweet as possible and exclude the rants and rages about stuff not working properly...

    PLAN is to have a boschd XUD9 engined 205 with an IHI15 turbo gearbox mounted

    So, purchased a standard, Peugeot 205 1.8DT for a grand total of 70 in April time?. It had 1 weeks MOT left on it, had taken a hit to the front and was pretty grimey and moldy all over. After closer inspection, I could see the damage was nearly all cosmetic (apart from headlight and indicator).
    Fixed up the main issues for a grand total of about 30 - scraps, hammers and cable ties - chucked in for an MOT and voila, passes first time, no advisories. and yes, it was a legit MOT.








    Next up, set about sourcing an engine - found an XUD9TE on ebay, so got it shipped down to the lonely island i'm on - albeit with a few issues again - the seller, typical salvage junky, ripped and smashed the s**t out of the engine - but, short of it, managed to salvage/swap most broken bits with the XUD7

    New engine awaiting to go in...





    ...AND engine out




    Whilst the engine was out, I set about ensuring it was ready to back into the 205 - usual maintenence - cambelt kit including pumps etc. And ensured that it was fully compatible with the 205 setup - pipes, auxillary setup, oil cooler and fitted a bosch pump in the process.


    Then, take one XUD9 lump, attach it to a crane




    Swear, scream, smash and growl until.... it fits...




    ...and the sorry, salvaged XUD7






    Then, sorted out plumbing, fuel etc etc, and we have life







    Then, it drove after again, issues with clutch etc, but it lived and drove under it's own steam






    WHICH brings us pretty much to today - at the weekend I wired up the battery to the boot where it's been relocated.








    Welding is well under way for the turbo as is sourcing of piping. Intercooler is here and waiting to be bracketed up.


    Will update as more happens
    Peugeot 205 XUD9TE Project - gearbox mounted turbo. - https://www.pug306.net/forum/threads/150939-XUD9TE-engined-205-gearbox-mounted-turbro-(pic-heavy)

  2. #2
    Active Member ginge191's Avatar
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    Oh, and excuse the squeaking at end of video - that's the old aux belt
    Peugeot 205 XUD9TE Project - gearbox mounted turbo. - https://www.pug306.net/forum/threads/150939-XUD9TE-engined-205-gearbox-mounted-turbro-(pic-heavy)

  3. #3
    Prospect Parksy87's Avatar
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    Should go like stink bargain price too


  4. #4
    Active Member ginge191's Avatar
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    thanks! Fingers crossed it shall drive with boost at least.




    Turbo has been drilled and tapped for clocking. Next challenge - mounting the actuator.

    Oil lines will be made up soon - just got to measure the length needed once turbo is in situ
    Peugeot 205 XUD9TE Project - gearbox mounted turbo. - https://www.pug306.net/forum/threads/150939-XUD9TE-engined-205-gearbox-mounted-turbro-(pic-heavy)

  5. #5
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    Can I just as what made you choose a ihi 15 ?


    306 HDI td04l coonvertion r70 pump 3" straight through stage 3 six paddle clutch fmic still on stock map a the min tho

  6. #6
    Active Member ginge191's Avatar
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    Quote Originally Posted by jack 17 View Post
    Can I just as what made you choose a ihi 15 ?


    No reason in particular, but, it was cheap, had its original flanges and downpipes so required less work to fit and was cheap.

    Technically, it flows very well for the XUD9 power band also.

    That and no one has used it yet
    Peugeot 205 XUD9TE Project - gearbox mounted turbo. - https://www.pug306.net/forum/threads/150939-XUD9TE-engined-205-gearbox-mounted-turbro-(pic-heavy)

  7. #7
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    Very interested that's why I asked as Iv never seen anyone use it looks cool mate


    306 HDI td04l coonvertion r70 pump 3" straight through stage 3 six paddle clutch fmic still on stock map a the min tho

  8. #8
    Active Member ginge191's Avatar
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    Quote Originally Posted by jack 17 View Post
    Very interested that's why I asked as Iv never seen anyone use it looks cool mate


    Correction sorry - it's an IHI RH5 blower. Suited to 2.5 DERVs

    http://www.dieselevante.it/turbochargers.asp?idfam=RHF5

    Cheers - well it's a hefty turbo, it's old school and easy to work with...
    Peugeot 205 XUD9TE Project - gearbox mounted turbo. - https://www.pug306.net/forum/threads/150939-XUD9TE-engined-205-gearbox-mounted-turbro-(pic-heavy)

  9. #9
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    Iv ran a tdo4 16g on a 2.0 8v hdi boost around 2900 rpm
    Tdo4 13g on a 2.0 8v hdi boosted around 2600 rpm
    And currently running a td05hl on a 2.1 16v hdi boosts around 3400 rpm witch is far to large but you live and learn. When does yours boost ?


    306 HDI td04l coonvertion r70 pump 3" straight through stage 3 six paddle clutch fmic still on stock map a the min tho

  10. #10
    Active Member ginge191's Avatar
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    It's in final welding stages at the moment and because the 205's don't have a rev gauge it'll be guess work
    Peugeot 205 XUD9TE Project - gearbox mounted turbo. - https://www.pug306.net/forum/threads/150939-XUD9TE-engined-205-gearbox-mounted-turbro-(pic-heavy)

  11. #11
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    Oh right I see


    306 HDI td04l coonvertion r70 pump 3" straight through stage 3 six paddle clutch fmic still on stock map a the min tho

  12. #12
    Active Member ginge191's Avatar
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    Productive day all in all.

    Began by getting the car up and securing the power cable..




    I did use a second P clip lower down but didn't photo that - all out the way and tidy



    Then got set inside and sorted/fitted gauges and the cheap-tack-tastic pod holder...please don't judge - why anyone went to the effort of hydrodipping this crapppy tacky carbon i have no idea




    and finally made large progress with the manifold

    - got the pipe to turbo fairly sorted
    - made first mount for the turbo
    - got adapter pipe for the exhaust side ready

    And excuse the gaps on the corner - it's a tight bend at the end - but by the end of the evening, it's all filled and ground back to reveal a nice seal all the way round


    New position of turbo









    Peugeot 205 XUD9TE Project - gearbox mounted turbo. - https://www.pug306.net/forum/threads/150939-XUD9TE-engined-205-gearbox-mounted-turbro-(pic-heavy)

  13. #13
    Prospect Parksy87's Avatar
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    Dude if it works it works regardless of what it looks like, although saying that it doesn't look too bad


  14. #14
    Member TwinDrags's Avatar
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    Very interesting, always fun with engine builds, and especially boost builds
    Last edited by TwinDrags; 20-12-2016 at 12:05 PM.
    The JDM Pug 306 Project: http://www.pug306.net/forum/threads/149606-JDM-Pug-306-PH1

    ZX 2.0 16V Project: http://www.pug306.net/forum/threads/150607-Citroen-ZX-2-0-16V-clean-up

  15. #15
    Active Member ginge191's Avatar
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    Many thanks

    Today saw a lot more work.

    - Installed piping for boost gauge and fuel pump
    - Fitted the oil feed (return line is on the way)
    - Finished welding manifold to turbo
    - Welded up the flange
    - Began cutting and welding for exhaust
    - Fired it all up (with oil drain into a bottle) and all is well








    Peugeot 205 XUD9TE Project - gearbox mounted turbo. - https://www.pug306.net/forum/threads/150939-XUD9TE-engined-205-gearbox-mounted-turbro-(pic-heavy)

  16. #16
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    Good progress
    Bork Pictures Project Alloys HDi 170bhp @ 3450RPM, 284.5ft-lbs @ 2900RPM -

  17. #17
    Prospect Parksy87's Avatar
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    Get it finished already


  18. #18
    The Brain Dturbo90's Avatar
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    SLEEPER

    nice to see a 205 being saved from the old scrapheap

  19. #19
    Active Member ginge191's Avatar
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    Update on this - Exhaust is FULLY attached now, oil return is plumbed in.




    ABSOLUTE final thing is to plumb intake piping and intercooler, chuck on a fresh MOT and she's good!

    And when i say good, i mean she'll be up for sale
    Peugeot 205 XUD9TE Project - gearbox mounted turbo. - https://www.pug306.net/forum/threads/150939-XUD9TE-engined-205-gearbox-mounted-turbro-(pic-heavy)

  20. #20
    Active Member ginge191's Avatar
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    And she's done

    pipework is to be desired... but it's functional.

    Runs as should - for an OEM spec Dturbo engine. Yet to have some time fiddling with boost and fuel, but, as far as a 1.9 XUD 205 goes, it goes!

    This is up for sale as of now - open to all offers as it's either going to get stripped or scrapped. Purely because my eyes are on the next project already.



    AND IT'S NOW FOR SALE

    http://www.306oc.co.uk/forum/showthread.php?tid=35838
    Peugeot 205 XUD9TE Project - gearbox mounted turbo. - https://www.pug306.net/forum/threads/150939-XUD9TE-engined-205-gearbox-mounted-turbro-(pic-heavy)


 

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