Replacement daily hack!

[lozz]

ibet it runs better with the egr/pipe work cleaned out,

[dgt]

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

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

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

Still plenty to do, all on the cheap...

[lozz]

Angle grinder will sort the Armour on the pump

[dgt]

I'm enjoying my new hack quite a lot

More pictures for talking!

First, it didn't take me very long to be at it again...


Lack of heat was annoying. Out with another motor


I had my suspicions that the exhaust was not the best. So I got this one from a Xantia


I was right




Yes, they don't interchange


Oh look, the remains of the old turbo


Didn't stop me!


Back to that later....

For now, I'm using a full straight through. More on that and why later too!


Next, fuel flap and thermo


Old one blew away!


Clothes pegged

Decided to change the rad too as the old one was iffy




New but dirty rad


I tried to fit the Xanti-cooler but it's different! Too short



New rad in. This was a curse to put in!


And thermo


Onto the seats




And parcel shelf


For this


A pet hate


Solved


Refitting all




To the front






Speakers




Xantia cat and D8/D9 hybrid exhaust!!!



Backbox too


Then general cleaning








A lonely dark pic in a car park!


The straight through in action...
MWOCmEi1TE0

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

Engine swap scheduled fairly soon

[lozz]

That exhaust sounds good mate,

[dgt]

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

First, a decent pic of the front of the car


Boot mat got the bin


Better


Removing the GT15 off the other engine


The problem


Full set of wheels at last! Changing tyres




Newish rubber


Bought a Transit pump


Ashwood trim


Back to those later...

Ripping the engine out





Taking more bits off the other engine




The oil leak


The mess left behind


Cleaning up...



Transferring the loom. Old one was butchered in places


Oil switch had to be changed...


Cleaning up all corrosion


Pump on


Swapping flywheels


Back in


New o rings needed



Shafts in



Oops... Thank goodness for taps!


Hose on...


....and the high pressure seals let go, my nice new oil all over the yard back to the car a week later...

Back to the Transit pump









This will be going onto the 406


End of that long week


Old vs new


Why it let go


New pipe


On the road again buuuuut.... The waste gate sticks open. Why me

New passenger foot trim


Trying to loosen up the wastegate


Then the exhaust fell off....


A pikey bodge for now


A random new inhabitant of my car


Foglights needed attention badly





New screw needed


Lack of clock light was annoying me




Yaaaaay!!!!!


Upside down vent



Just 2 weeks.... Fairly dirty already!


Toolkit maintainance


Assembled again. Ashwood trim fitted


The vent is missing?


And finally for now, wheels and washed


Hopefully the next update will be fairly interesting

[Bailes1992]

Boost gauge looks 'Familiar'

[dgt]

Boost gauge looks 'Familiar'

http://i52.photobucket.com/albums/g16/B ... 631079.jpg

Wahey!

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


Beside a GT15


And 4 snow pics....





I have to figure out how to adapt the turbo to fit...!

[Bailes1992]

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!

[Captain Jack]

Nice pics and work! You wanna work on my car?

[Sonia406]

Nice pics and work! You wanna work on my car?

I was just about to write the same

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

[rwb]

Wow

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

[Nikolov]

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?

[dgt]

Wow cheers for the comments!!!

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.... Sort of in the pics below! But it worked

Nice pics and work! You wanna work on my car?

Not the first to ask....!

Nice pics and work! You wanna work on my car?

I was just about to write the same

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

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

Wow

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

It needs another clean inside already....!

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):


Picture from here

I'll do a mini update....

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

Turbo stuff



Needed cleaning



Clocking was all wrong, compressor housing needs clocking too


Wastegate valve adjusted round the right way...


To the boost guage


Handy hook


Wiring


Almost right!


Sealing where I ran the tubing....


While I was at it, changed the replaced fuses for originals



Not the cleanest...


A fuel filter changed...


Oh dear.... 5k miles....


I haven't a clue what this is...



Plenty left to do yet....!

[GingerMagic]

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.