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Paul_13

[Engine_Work] Puff The Magic Dervgon

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Paul_13

Here's the story of my 5 door derv runabout.

 

Pretty much been in the family since new with only 1 additional owner but my Dad bought it back off him.

 

Originally started with the lovely beige interior which was quickly disposed off!

 

At an early age of ownership the front running gear was swapped to 1.9 gti running gear, which proves to be one hell of a lot more stable than base model!

 

I also swapped the front brake calipers to 1.9 gti items as the 1.6 brakes had given up the ghost and when the pad locking bar went walkies on the way to driving to work in Brighton it was time for their farewell!

 

 

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Paul_13

Out with old

(NA 1.8 D with 182k on the clock and still going strong!)

 

IMG-20130323-WA0004_zps2ef484bb.jpg

 

IMG-20130329-WA0002_zps867b4797.jpg

 

IMG-20130329-WA0003_zps022b5504.jpg

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Paul_13

Some very perished fuel lines

 

IMG-20130311-WA0005_zpse911d770.jpg

 

Lovely veggie goodness!

 

IMG-20130309-WA0002_zpsf02d7efc.jpg

 

Don't any pictures of the new engine installed, but basically the specs are:

 

1.9 Dturbo engine out of a 405, Bosch pump :) T2 turbo and I believe possibly a Hdi box.

 

Here's a pic of halway through the gov mod:This basically replaces a spring on the cradle which limits the fuel delivery over certain rpm. Most people shim them but Ryan had put a stiffer spring in and I was basically the guinea pig of his modification :lol: It's worked well! Full on fuel all through the rev range.

 

IMG-20130601-WA0009_zpsf21affff.jpg

 

Next was the LDA pin modification (boost pin)

New ground down version vs. old

 

IMG-20130601-WA0012_zps05cf67bf.jpg

 

Where it came from

 

IMG-20130601-WA0011_zps56c83476.jpg

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Paul_13

The spindle was adjusted so there was more travel on the throttle and because of this I needed more travel on the pedal, so a quick modification was needed!

Excuse the bodged boost hose! Also bent the accelerator pedal to gain more travel!

 

IMG-20130601-WA0006_zps65289224.jpg

 

IMG-20130601-WA0013_zpsaa5903bc.jpg

 

The air filter I had on there was a bit restrictive

 

IMG-20130628-WA0007_zpsd14d4c40.jpg

 

Thought I could smell a burning smell! This was resting on the turbo

 

IMG-20130628-WA0004_zpsaca20ec0.jpg

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Paul_13

The plan was to use this front mount intercooler off a BMW e94

 

20130426_211956_zps5bc3713b.jpg

20130426_212034_zps0c7a2660.jpg

20130426_212024_zps744dbaee.jpg

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Paul_13

Had a bit of a hiccup when I decided to tighten the wastegate arm on the actuator. I'd manage to flatten the thread on the arm.

So I had to take the actuator off and take it to work to fix it. I ended cutting the flattened part off and threading the "eyelet" back on which means the wastegate will be firmly closed all of the time and resulted in 31 psi of boost through the poor turbo when I turned up the fuel up!

 

Needless to say it felt rather rapid at this point, only downside is the top mount interwarmer was hot enough to fry an egg on! (As i had not fitted the front mount)

 

I sourced a fmic adapter as the sale of the Xantia manifold fell through :(

 

Next modification was to get rid of the restrictive fuel filter setup and increase the banjo size.

Ordered a 10mm banjo off ebay and a 10mm fuel filter.

My reason for doing this is the inlet hose to the bosch pump is around 7mm in diameter and if you are running veg oil becomes a bit restrcitive.

 

IMG-20130906-WA0004_zpsd885bebd.jpg

 

Off came the fuel filter housing

IMG-20130906-WA0002_zps7320928e.jpg

 

The new fuel filter and banjo setup

IMG-20130906-WA0000_zps87e64d73.jpg

 

The difference is night and day, it doesnt feel strangled up the rev range and pulls considerably better!

Edited by Paul_13

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Gman

Looking good Paul, looking forward to going for a ride in it when you next bring it over.

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aldworth33

We've got a van at work with one of these workhorses in I think, might start having a play as it's pretty soggy top end. Looking good tho mate can't beat cheap DIY performance mods

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Uberderv

Looks good, how easy was it to get the top of the pump back on after the gov mod? I think your fuel filter might be on the small side though, also the filter heats the oil through the metal swirly bit.

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Paul_13

A little bit tricky, you just have to wind the fuel screw out fully then it makes life a lot easier!

It's the only filter I can find that has 10mm connections on.

A few people use the audi tt filter but it only had 8mm connections.

 

But compared to the previous setup the fuel filter is more than adequate!

 

I haven't noticed a difference in the mornings yet. If I'm moving it's not a problem.

I think there's a lot of myths surrounding diesel tuning on XUD's

Edited by Paul_13

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Paul_13

I thought i'd get rid of the plastic pipe which feeds the intake of the turbo and replace it with a less restrictive setup (eventually)

I bought a reducer 90' bend off of Ebay and a bit of flexi hose and an air filter. Excuse the long flexi hose it's a temporary measure while I get the FMIC sorted.

 

20130810_163518_zps581a703a.jpg20130810_163524_zpsd3ba502b.jpg

 

My rad lowering bracket, a piece of 20 x 40mm unistrut from work with a couple of 90' cleats and some 12mm bolts and nordlocks.

 

IMG-20130830-WA0001_zpsc2c2a63d.jpg

IMG-20130830-WA0003_zps51603418.jpg

IMG-20130830-WA0006_zpsfd4eda35.jpg

Edited by Paul_13

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Paul_13

15" steelies which look awesome!

IMG-20130823-WA0009_zps43414822.jpg

But came off a day later as they rubbed soo bad

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Paul_13

Lowered the rad and makes a huge difference to the inlet temps , I can actually put my hand on the intercooler after a sprinted drive and not burn my hand! Bought some slim line fans off of ebay and they've done the job nicely!

 

IMG-20130907-WA0004_zps7d1854c7.jpg

 

Next I moved onto mocking up the BMW front mount, now if I had a GTI valance fitted it wouldn't be a problem! But because I'm trying to fit everything behind a base model valance, it's a task and a half!

 

IMG-20130907-WA0002_zpsd6fbb34e.jpg

 

IMG-20130907-WA0000_zps3b9c2573.jpg

 

IMG-20130908-WA0000_zps1421d0a9.jpg

I don't think the police at work would appreciate this!

Edited by Paul_13

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Paul_13

After deciding that the BMW would not fit I opted to go for a universal cooler

 

universal-x-small-fmic-bar-plate-design-

 

I couldn't find another that fitted comfortably, but this one will do the job the adequately!

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Paul_13

Plus a few silicone hoses off eBay I have a front mount which will fit!

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chipstick

What you need is a genuine Peugeot roof rack which I happen to have for a 5 door ;)

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Paul_13

I'm ok, have thought about it a few times as I knew you had one. Out of interest where does it fix to?

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chipstick

Grips up under the roof at the top of the door shut and clamps down on rubber feet on top.

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Paul_13

Bit of an update for you diesel loving fans:

 

20130928_153214_zps61454865.jpg

 

I bought a random filter from the local motor factors. It's only 8mm connections and I wasn't too pleased with this. I've been after a 10mm inline filter and have really struggled to find one until now. http://www.inlinefilters.co.uk/Filters-Fuel/Inline/Metal/FFG-FF5079 Got a few of these on order now

 

A few bits turned up in the post:

 

IMG-20130930-WA0004_zps84cc5c0e.jpg

 

IMG-20130930-WA0006_zps4bebaaf3.jpg

 

IMG-20130930-WA0008_zps103f91ef.jpg

 

IMG-20131001-WA0000_zps44593fa9.jpg

 

Here's a quick mockup of the front mount setup

 

IMG-20131003-WA0003_zpsb364e62b.jpg

 

And pretty much installed:

 

20131004_173858_zps62a09cc4.jpg

 

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Just to see what it's like unfiltered!

 

Grille sticks out a bit, got a bit of chopping to do!

 

20131004_182700_zpse877f562.jpg

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Paul_13

And a hint of whats going on next!

 

BuisEwBWkKGrHqJigEv1z5ktBMwBbHNQ_3_zpsf4

 

IMG-20130929-WA0019_zpsd3613638.jpg

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kyepan

this is all kinds of cool!

 

i want to see a photo with puff making a cloud of derv

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Paul_13

Let's say I'm looking forward to a nice crisp cold morning!

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Dundy53

Proper stealthy, I like it!

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Paul_13

Was like a rocket on the way home earlier!

 

I found a 10mm filter at last!

 

20131008_141941_zpsc6deb882.jpg

 

Works a treat!

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Paul_13

this is all kinds of cool!

 

i want to see a photo with puff making a cloud of derv

 

Might have to have a passenger taking a photo :lol:

 

You won't be able to see much :ph34r:

 

It's strangely addictive! Diesel tuning that is. Got the xsara quick rack going on at the weekend!

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