2.2hdi tuning

[Welly]

Peugeot probably had the experience to think "hold on, when one of these flaps comes off........"

Maybe. But perhaps it was because they KNEW it would break (like the COMM2000s, the wiring, the droplinks etc) but didn't want to be bothered with having to do an engine rebuild when it did...

Already had it covered mate

[Doggy]

Maybe the German place thought it would be impossible for any of their components to 'fail' at some point, being so well made

We have extensive experience of allegedly being the only customers to 'break' machinery from a prominent German manufacturer, (only to discover it happens to everyone else too), so I would not be in the least surprised to find that was their mind-set.

To illustrate the point, once the M57 engine's appetite for swirl flaps was recognised, the later M47 was instead fitted with fixed, swirl-inducing vanes cast inside the inlet manifold. These, despite their complete lack of mechanical fixings to come undone, still managed to detach themselves with terminal consequences for the engine.

Imagine the flak Peugeot would get for this level of incompetence.

[mattMPH]

So the swirl flaps fall off off. I know the gm cdti 150's have problems with the solinoids sticking either open, closed or half closed.

Take it 90k is just ran in on one of the hdi's. Is there any off the shelf engine mods or is most stuff custom fabricated. I'm sure i can find out the limit of the clutch and box off a good freind of mine

[steve_earwig]

So the swirl flaps fall off off. I know the gm cdti 150's have problems with the solinoids sticking either open, closed or half closed.

My brother has one of these in a Zafira, I was looking on some GM forums and solenoids sticking isn't half of it - the shafts wear in the head too... I've just been talking to him via Skype and the alternator's gone now - £700 (450 of that seems to be labour, it would be cheaper to fly my mate the mechanic over there to do it ) It's 6 years old, done few miles and he's already been through cleaning out & finally replacing the EGR, so it's for the chop.

Take it 90k is just ran in on one of the hdi's. Is there any off the shelf engine mods or is most stuff custom fabricated.

I doubt you'll find much off the shelf stuff - it's just not "that" sort of car

To illustrate the point, once the M57 engine's appetite for swirl flaps was recognised, the later M47 was instead fitted with fixed, swirl-inducing vanes cast inside the inlet manifold. These, despite their complete lack of mechanical fixings to come undone, still managed to detach themselves with terminal consequences for the engine.

Sorry but

Imagine the flak Peugeot would get for this level of incompetence.

They'd never hear the end of it I'm told Mercedes had a similar throttle issue to Toyota a few years back but it was quietly buried.

[mattMPH]

See the problem i'm finding is the lack of already tuned 2.2 hdi's to gain ideas from. I'v seen vnt turbo's fitted to the rover l series, methonal injection on the gm cdti engines but there really is a lack of 2.2 hdi's.

[Welly]

Problem is there aint many people who buy a diesel motor and then go hell-for-leather in tuning it up, so, there's not really a market there. I saw a guy on the VW/Audi forum who'd tuned his Skoda Labia VRS to within an inch of its life and all it did was spin the front wheels and smoke a lot

Tuning a modern diesel for better performance is pretty much limited to a re-map, a better intercooler, and a free-flowing exhaust at best. After that you're in experimental territory and on your own

The other issue to consider once you've made your 406 move more quickly is getting the thing to stop and take corners nicely. They were never intended to be hooned about like a hot-hatch rather they were made for eating the miles in comfort

[mattMPH]

As for stopping braided lines with some ap racing brake fluid pushing some tarox discs and pads would soon sort it.
As for handling i'm sure coilovers are avaliable and if not i'm sure a set can be made to fit.

Not sure how much room is behind the bumpers on the 406's but i'm sure a fmic would fit from what i have seen. At the moment not researched the turbo side of things. Presume being a quiet modern engine they'll be electronically actuated meanjng boost can be raised with the remap. As for the turbo size i need to look into that abd find out the sizes of the turbine and compressor wheel to see if there is any chance if finding a hybrid.

We'll see what happens wheb i find a nice d9 to play with

[highlander]

Wasn't there someone with a 406 Estate who had a front-mounted intercooler fitted? As I recall he'd had to cut a huge hole in the front of the car, or mount it externally, or something.

Good luck with your tuning, let us know what you do and what the results are.

[406loon]

The other issue to consider once you've made your 406 move more quickly is getting the thing to stop and take corners nicely. They were never intended to be hooned about like a hot-hatch rather they were made for eating the miles in comfort

Thats easy on the 406;- brembos, braided hoses, front strut brace, rear lower brace, a set of 17'' light alloys with 45 profile tyres, some coilovers and poly bushes and it will handle a treat - all readily available bolt on modifications. They handle well out of the box anyway and the stock brakes arent too bad either.

As for tuning engine then changing turbo route will be expensive. It will definatley need mapping after fitment, probably bigger injectors and a fuel pump to match. The stock intercooler will probably flow enough to be honest.

Parts wise:- Hybrid turbo, injectors, pump, roling road session and I would have thought it would need an uprated clutch aswell. Black diamond do them and from memory the most uprated one they do is £450 I reckon A budget of £2.5-£3k would not leave you with any change to do all that. Would also need a larger downpipe fabricating.

Also, no one knows how strong the bottom ends are on these 2.2s - what thier tolerances for tuning are. Crank the boost up too high with a bigger turbo and you could end up throwing a rod or melting the pistons. Bend rods and rods exiting the block are not that uncommon on common rail diesels. I believe for tuning the evolution of the 2.2 engine, found in the mondeo ST TDCi is a better engine for 200bhp+ tuning.

[mattMPH]

Yeh the mondeos are better as there has already been many tuned st tdci's. Theres only one problem................................................ i HATE fords, with vengeance

[406loon]

Yeh the mondeos are better as there has already been many tuned st tdci's. Theres only one problem................................................ i HATE fords, with vengeance

Trouble is the 2.2 hdi engine you are on about is at least part ford. It was designed jointly with PSA group with Ford at the Dagenham R&D plant. The Mondeo ST TDCi is a very capable car, impressive spec, handling, looks, very moddable and easy to get 200bhp+ out of. I wouldnt hate a car like that, its worthy of respect. Alot of Peugeot's best tech guys went to work for Ford, which is why new fords namely the Focus and Fiesta mk6 onwards handle so well.

As for Modifying the 406. I am trying to mod mine. I have owned her since mid July and you will see what I have done so far in my sig below. There is very little out there in the tuning department, but that makes it all the more worth while.

[bytecode]

Wasn't there someone with a 406 Estate who had a front-mounted intercooler fitted? As I recall he'd had to cut a huge hole in the front of the car, or mount it externally, or something.

Good luck with your tuning, let us know what you do and what the results are.

Yeah, I think that he was retro-fitting a 110 BHP Intercooler to a 90 BHP (as we 90 drivers aren't privileged enough to have a cooled charge :'( we just lust after the 110's as the glide effortlessly by!)

Looking at mine, there is space for a vertically mounted intercooler, on the nearside (LHS) of the radiator, there's a black plastic "blanking plate" sitting there, keeping the area "clean and ready" for when I finally buy one... It seems to have mount points that may be suitable, so I guess it's just a case of attacking it with a dremel and some sandpaper.



I was planning upon stealing the one out of my Rover 418 (XUD7TE Engine) but it had been sitting around for so long that it had turned to a lovely impression of a box of (rusty) glitter.

[Welly]

Fitting an intercooler to a 90 won't do anything, it is the amount of fuel being injected that gives the performance (up-to the point where it needs a 'lid' keeping on the charge temp) too-cool intake temps on a diesel is not good as it affects the flame front and 'quenches' it. Apparently 15deg C is a 'happy' charge temp.

A 110 injects more fuel and makes the exhaust side of the turbo hot, which, together with the compression of the charge air, raises the inlet temp to a point where it could do with cooling a bit - hence the intercooler. A standard 90 doesn't need one, in fact they can even be remapped to 120bhp and still with no I/C. The only time you'll suffer then is maybe a bit of heat soak on a very hot day and the performance will drop off a tad and maybe make more black soot through an incomplete burn.

[Frenzy406]

Hi there, it's great reading about others who want to push/find the limits Of the 2.2hdi, I too am working on getting as much as I can out of my estate, updating parts as they become useless or break ;)

The estate with the Fromt Mount Intercooler might be mine, I was at Pugfest last year ... ;)

Read the topic " Pugfest"

Yes I fitted it as snug to the rad as possible, then cut the bumper to fit around the Intercooler. Being my daily driver I haven't got around to fitting/making a nicer bumper yet, I'm mainly happy that it performs well for now, hopefully better when I get around to finishing the turbo upgrade/equal length manifold/3" straight thru stainless system I have planned and half built ;) the aesthetics tend to take a back seat ...

It's true that there's understandably not a lot of choice out there for modding a 406, but i agree that's what makes it interesting for me, to design, make an be different ;)

So Any advice / other sound of other projects welcome !


viewtopic.php?f=5&t=15622

[Frenzy406]

Wasn't there someone with a 406 Estate who had a front-mounted intercooler fitted? As I recall he'd had to cut a huge hole in the front of the car, or mount it externally, or something.

Good luck with your tuning, let us know what you do and what the results are.

Hi there yes that's me
Still got my estate, off the road arm for a rebuild due to head gasket failure :/

Some More mods to go in there on rebuild tho ;)

Kind regards, Neil