Replacement daily hack!

[dgt]

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.

Cheers! I'm glad to hear my posts are some use

I guess here is the next chapter...!

Decided to pull my finger out of my ar.... mchair and get this pump built

First: Convenient DXH on a pallet


11mm bolt missing....


Puller needed


These Polo driveshaft bolts are the right size, length and have collar for locking the sprockets. Stronger too


Slack...


That was a pig to take off.... Thankfully I didn't lose the woodruff key!



Prep for removal


Off! Tamperproof, boooooo-earns


Yeah right



I've removed the throttle assembly, max rpm and idle screw to access the 4 top bolts properly


The 414 vs the 494. The 414 has much cleaner internals



Gov assembly's compared



The mutant result


Next: the head


The head off


The 11mm plunger vs the 9mm!


And distributor heads


All this effort for those bits

I decided to install it this way


New O ring


All ready to tighten down


Distributor valves



Somewhat finished... The bottom half is anyway


New top seal


Throttle shaft seal


A fiddly job...


I set my pump from full throttle



Finished!



The next day...

Needed cleaning



Better


Back onto the engine


Re-timing


A lack of grease was rectified


I couldn't find a bung so I had to put on a GT15. Still an arse to put on despite being on a pallet!


Cabling up...


So does it work?
21pxJtLNICQ

Sweeeeeet

Decided to clean my car too

But first, I'll need to find some way to fit this!


After I cleaned the car, I cleaned the glass


Then broke out some polish



Halfway there...


Mirror


I ran out of light thus need daylight photos... The last thing I did was replace a blown foglight


Plenty left to do....!

As a bonus, I found this vid with the old engine in it...
c0bhEu42Ixg

[jonsowman]

Talk about making it look effortless! Well done, great stuff. I enjoy reading your threads

[dgt]

Cheers! I enjoy doing this stuff, more than happy to share!

Been long overdue.... But an update!

Not much happened in between as I'm bogged down with college and other projects.... Alas, summer and plenty of time

So I'll start off where I left off: A shiny car



Of course I wasn't happy with that so it got a full work over later that week








Looked well at night!


Service time...


While I was doing that I decided to change my boot trim and whack a dent out!





Much happier with the pocket


Then some suspension altering occurred....




Quote fed up of my cracked tail light so I replaced it with a new one





The leveller broke one night.....



Eh.... Yeah!


For the crack I tried the projector lights.... Thoughts?




And had to change my front tyres with a quick wheel refurb!






Before and after!




A quick camber adjustment.... Before


After


So as it stands!


As for the turbo.... How could I forget that!








Beside a GT15


And on you go!


Still plenty to do.....

[dgt]

With a few issues to address with the TB25, not much more I can do for the mo....

Plenty of driving about though. With 20psi of boost and a Transit spring in for a gov the power is there when I need it.... It'll do for now




Gl__nJTOKIk
Q6v7vAARDyo

Quite rapid as is

[dgt]

I learned how to work picasa somewhat better!

Fuel filters don't last long here due to the washed diesel epidemic


5k Miles


Exhaust boo-boo



It'll do for now....



I got a D9 console as I as pestered with botles flopping about everywhere



Quite.... Dusty



3 completely different cig lighters....


Yaaaay!


Only thing left was the big gaping hole to fill.... So I made up a filler







Fluid change was a must


Bulb change as I couldn't see the miles for a while!


Wind deflectors are a must



As for my turbo swap project, I couldn't justify spending more time on it so I gave up.......


















......And got a bigger turbo instead


Beside a GT15



Beside a similar sized turbo as the TB2509!


I didn't hang around






And again beside the GT15, on an XUD mani, correctly clocked


Just the oil drain pipe, wastgate sampler and downpipe to worry about, apart from a bit of adapting the rest was almost bolt on

With the pace the turbo is going at the engine should be in soon

[dirtydirtydiesel]

Have been following this thread with great interest, it's looking good
Can't wait to see how it performs

[dgt]

And the saga continues....

First, Irish laundered diesel problem in a nutshell. Off with the sender


Traditional ring too big for hole



Oh dear




Back to the turbo after a lot of experimenting with pipes I found that a shortened thermostat/ heater pipe from a Fiesta on a modified Merc oil return pipe works as a return



Box off reveals this beatuy


Newish glow plugs


Original thermostat. For shame!!!


Cleaning the fuel heater


Polishing the LDA hat to a millimetre of its life


And rocker cover


Swapping all the little bits and bobs.... Xantia to 406, a lot of differences!




The standard pipe fits with a bit of manipulation



Sadly, not a hope!!!


So out with the consaw and a slab of steel


Drilling to fit


And this was timing to perfection.... This happened as I almost had the engine ready!
4P37TSuzjog

Sigh....



Onwards and upwards Pump fun.... Swapping dynamic advance shims to Transit ones



Next, wastegate woes..... Finding a way around it was fun








A very crude EGR blank


30k mile clutch..... It's 3rd flywheel


Refurbd pump top


Later that evening....


Next day


But..... Does it work?
PQFjVs32LCQ

Oh yes

Still needs adjustment, downpipe now fouls the linkage but I'll get around that

Looking foreward to a test drive when I have it set up the way I want it!

[dirtydirtydiesel]

Looking good dude, the effort you put in is mega, are you going to plumb in a intercooler cos you'll need it with th boost temp's that bad boy could run

[dgt]

Looking good dude, the effort you put in is mega, are you going to plumb in a intercooler cos you'll need it with th boost temp's that bad boy could run

Cheers! They come with an intercooler as standard, was looking to fit one from an Iveco but it's huge Something else might crop up though!

More of a how I solved it rather than an update but it may help someone in asimilar situation

After getting it running, it wasn't going right.... Time to adjust this pump!

LDA adjustment (star wheel + smoke screw)


Relocating the linkage for a shorter throw. Also adjusted the position of the arm on the splines


Adjusted the fuel screw. Stubbys are handy for such small spaces!


Beware screwing out the pump when the car is running, I shorted out the stop solenoid and blew fuse 25 in the main fusebox

Much more room to access the exhaust bolts


When all that was done I went for a test drive. All grand until no power atall It was creating a vacuum!!!!
dnd7Pn5DVDM


Must be the pipes.... No, all clean.

Must be the cooler



No, it's fine

Must be the wastegate, so I sealed it shut


No. I was going out of my brain

Then I tried it without a filter..... Success!!!! It's got the bin since

So I've been enjoying my car all evening since, just needs further tweaking in places and perfect
u4Dq6Wckg4U

[dgt]

It's just more developing for me.... Looking to try and fit a Sofim 2.8 air cleaner infront of the box!

For now, I've assembled a pipe from a Volvo and 2 Ivecos






Brand new tyres


Completed a long run happily enough too



And some vids of the turbo in action
WWYSPnXkcVE
xdjIn8HWMuM

[dgt]

Time I poked my head in here again

As of the 5th of Jan, I'll have this car a year

Since the K14-2 swap, this car is an EPIC daily driver. Very few can outpace it, as a young fella in a WRX found out one night at the lights

Not much has changed, although the car is in a sorry state at the moment more on that later...

Apart from that, what have I been up to? Enjoying my car and enjoying the way it goes!!!

I needed a filter, hated running de filtered...



One day on the motorway, I lost all power....

Back of the car looked like this after cleaning it that morning!


The culprit for my loss of poke


From a Xantia


And back on my way I went

Didn't clean the back of the car for ages after that


Small exhaust issue....



Only a small issue....



Mock up for correct length


Back on the road again Time to enjoy the car







However, I wasn't happy with the way it handled.... And lost diesel

So I got a small box of parts



After the linkage broke in an irritating manner, it was first on the change. Pikey bodged at the side of the road!



Better


Now.... The fuel leak....


Am thinking of fitting these


Painted the drums when they were off


Out!


Culprit


Cleaned the sender when it was out


Considerable hours later, after much swearing.....


Done! Arb bushes now, note it's feckin dark....


Much needed!


Needed to sort the downpipe


And weld another hanger


Job done! Next day was just configuring the exhaust.... Uh oh


Can't have that, emergency pikey fix!!!

Take a lump of a Stilo....


Cut it


Shape it


Bend it


Drill it


Now we hack the pipe off


Jam this lump of a coat stand onto the pipe.....


Weld it and a lump of a 106 box onto it....


Rivet the piece from earlier on...


And now we have a handy way of covering up a mess that would have needed a new bumper otherwise


Next was to sort an awful banging from the front.... I was sure it was the stabilizer

So I rooted this one out


Hmmmm....


Out you go!


Oh dear.....!


Honestly not surprised it went with the power from it

Messy job though


But that cured that

Strengthening the tail pipe hanger



See, coat stand


Then..... Disaster. Timing belt went Not overly upset as it was a development engine. But annoying to say the least!

To my inventory, out with a spare head..... No make that a full engine! Head for now


Now let the porting madness begin...












Can't wait to have that in the car.... Actually, I can't wait to have my car back full stop, I miss it so much!

How it currently looks...


But how am I getting about? Well, this is the daily hack for now....


RWD is addictive (I have gone through 4 sets of tyres ) but it can't hold a candle to the 406

Also that E39 isn't the blue one from earlier in front of the 406, I have 2 of them. It's a V8

What will my next update entail?

[dgt]

Time I poked my head in again....

Lets wind the clock back to March.... I needed my car back and fast. Onwards and upwards!



Getting there....


Pump off





On with the hybrid pump, static advanced


Sump off



I could eat me dinner from that




Many minutes later....





Pistons next



Bin


New!





Need the pulley



W/Pump, rollers etc



Diesel pump work







On with the pump lines again


Cleaned up my cam






Pump on



Injector plumbing


Studs and manifolds




In the car it went

New brakes



A week later, the accelerator cable snapped





So as it stands



Sounds as good as ever too
QyAyZpY7yHQ

KhdQyRPnUDE

[jonsowman]

I love reading your threads, fantastic work

You're going to have basically new 406 at this rate!

[dgt]

Cheers! But like all good things, they have to come to an end sometime

Time I closed the book on my fantastic daily driver

Since the engine was done I covered 4k miles in it in I think 6 weeks.... There was one week I had over 600 miles put up in 2 days, I was looking to blitz well into the 1000 mile week and beyond


However, on day 3 of that week, I decided to stop driving the car to sort out a small oil leak. Was running it on 5w40, it went through it very fast the one and only 406 ever to enter my garage to add to the list of legends that have graced those doors over the years



When I had that sorted, I put up the final 200 odd miles with new oil. The juddering was only getting worse and worse The last time I drove it I was merging onto a motorway when I lost all drive, the clutch completely rang I found out after. Not surprised really

So it had to be brought home on a recovery truck where it stayed at the front of my house for 6 weeks.

The last bit of work I done was to change a tyre on it, then replace the spare with the new wheel and tyre





The later that evening, I waved goodbye to my old friend. Literally heartbreaking to watch it being towed off


I know it's gone to a good place, I know the lad who bought it well, mad into XUD's too. He has it running too!

As for my next car? I can't see myself with another 406, as that one was very special to me and any other one just couldn't cut the mustard compared to it. Although I said that before about Alfas.... So you never know

For now, I drive a Mercedes C200. It has a welded diff I serviced it, sorted out a propshaft issue, got some 17's for it and slammed it. It's great for drifting



It's a really nice car but is a stopgap while I source parts for my next sleeper car: an Alfa 156 3.0. Initially I had a strict deadline to get this car running by but with the waiting time for parts and the stress it was causing me, I decided to scrap the deadline, use the Merc instead and build the 156 in my own time

Then when up and running I have a turbo to put on it.....


Should prove to be interesting when up and running!

So that's me done with 406's for now. I'll never forget my 2, for different reasons. But I'll look back with fond memories of this one in years to come

[dgt]

I think it's time I dropped in, as it's been a while...

I'll keep it very short and sweet: I bought it back years later and I still have it to this day. I haven't done very much with it unfortunately, but that'll change someday

I found a video of it afterwards from the outside, as I don't think any of the above videos do it justice... No diesel car I've driven since has ever been like this one!
r2Ut8rsAFQg

Did i buy another 406? Yes I did. I done some work to it too, but kept it a lot more civilized; I used a 10mm head with a GT20 from a 220CDI with the T2 housing machined to accept it and some other trickery
vJ8HhBzpJB4

What am I in these days? I've kept it French:


And probably showing my age... Sort of

Will I drop in again? You never know, but nostalgia is very real