Jump to content
reb

*actual progress klaxon* 205 Jr 2.0 HDI Build

Recommended Posts

17 hours ago, reb said:

It turns out I made a dangerous assumption about the ECU, it is in fact a SID801 which it appears isn't really at all easy to remove the immobiliser from. Therefore plan A involving bodgery and gaffer tape is go. At this point I just want it running, so am happy enough to just mount everything in a box in the footwell or something to deal with later. Unfortunately this probably means having to program out the alarm, I think? Maybe just bodge it so all the sensors and switches are permanently in a state of "everything is fine". I think I have a decent amount of time this weekend and next week, so this all may happen rather quickly without too much in the way of in-progress updates. The interesting bit will be uprating the rest of the car to cope with its new found torques I suppose.

Apologies that there's a lot of "maybe I'll do this" and not a lot of "I did this"!

If you still have a way to connect to the ECU via OBD, could you use an MPPS cable to remap the ECU and get the immobiliser/EGR deleted by these guys? https://www.hdi-tuning.co.uk/ecu-remapping/how-it-works.html it's £100, but the stage 2 remap at 155bhp would be amusing. I used them for my 307 and was very happy with the service.

Edit: sorry, I see this has already been suggested. As you were, good luck with the build!

Edited by Tepper

Share this post


Link to post
Share on other sites
12 minutes ago, snagglepuss said:

I have got a 120 remapped ECU if the numbers fit - already tuned by HDI tuning.  Sure we could do a deal on it.

 

It's got the egr and imboliser delete already done.

That'd be absolutely perfect, I have the existing ECU on my kitchen table right now so can check numbers when I finish work today!

Share this post


Link to post
Share on other sites

Alas it seems my ECU is completely different, I spent an embarrassing amount of time trying to make out numbers on it before realising the connector is different!

20190504_130401.thumb.jpg.2fa084cf57c2cc04e9f807720a43d64d.jpg

I suppose I'll have to get in contact with HDI Tuning soon and see what they can do for me.

Share this post


Link to post
Share on other sites

What do I do with the AC compressor and condenser? Obviously it's not being retained, and it's completely removed from the engine, Haynes keeps telling me to under no circumstances ever disconnect the refrigerant lines. Realistically though is there likely to be any refrigerant left after 16 years? It'd be handy to have it out of the way of swinging the engine out.

Share this post


Link to post
Share on other sites

My intention today once the engine was out was to set about readying the 205 to pull the xud out, alas the rain went from occasional spatters to all out monsoon not long after Keith left.

20190521_161300.thumb.jpg.6fcad366ef91f4b39903f5d5c1919446.jpg

This is how we leave the project for the day. I'm off inside to have a coffee and dry off my tools.

Share this post


Link to post
Share on other sites

Some slightly scary progress...

20190604_173322.thumb.jpg.512764b565e6b0c1cb60dc91b1165232.jpg

Easy does it...

20190604_173858.thumb.jpg.78d10866918cb321fb470712e42c30c8.jpg

Success!

20190604_174245.thumb.jpg.7c7a0eceb4f9ac88247258c1aaba4ec2.jpg

Gearbox robbed

20190604_183439.thumb.jpg.60887b2c29a2b3b278a9e3dfa3e5a354.jpg

20190604_183435.thumb.jpg.2f35023c5719d6c8c40e845649c5bca8.jpg

SPANNER IN THE WORKS

20190604_192304.thumb.jpg.1eeca9b1401f94c459dcb7ea8147495c.jpg

Rudimentary measuring showed that the mounting holes for the alloy mount from the XUD existed on the HDi block. Actually trying to fit it showed this is in fact not the case. The cast iron mount from the 307 is obviously completely wrong. I'm reliably informed that a 306 HDi bottom mount should fit, there were only two on eBay and both were in foreignland. Both slightly more expensive than I'd really like, but the one I bought is brand new and seemingly coming from a legit parts supplier rather than a bloke in his shed.

On the plus side, the gearbox went onto the HDi absolutely no problem, there was even a hole in the bellhousing for the flywheel sensor! It'll be coming off again today so we can put the engine on a stand to do the timing belt.

Keith goes home to Orkney for summer very soon, so I lose a convenient extra pair of hands which is slightly annoying. That means that the plan is to fit the engine without the lower mount for now. Engine and box came out as one, but it was oh so tight, so we'll be lifting them in separately this time as some of the angles involved coming out will be impossible going in. That's the plan for this evening.

I think this weekend will see it at the stage that all that's left to make it drive is fit the mount and shafts! Of course making it roadworthy will involve piping the exhaust gases away from the engine bay, but that should be easy.

 

Also, this happened:

20190605_145647.thumb.jpg.e711a804eeffc83215573e95e4d6ff54.jpg

This 3t jack makes being lazy so much easier. I do have to wonder what the insurance engineer that came to look at the Volvo that day thought of the various automotive madness going on in the yard.

Share this post


Link to post
Share on other sites

Looking at the completely bare engine bay in my pride and joy definitely induced a little bit of panic because I know about my tendency to put things off and I'd rather it didn't become one of those projects that never turns a wheel again. Double panic when the extent of the mounts not fitting was realised. Fortunately I'm hung up on the desire to have something genuinely quick that I built with my own two hands, so it WILL be done as soon as reasonable!

Some good money news came immediately after I posted too, so with some careful budgeting I can do a couple of extra things I was planning on delaying a while.

 

With that in mind, what colour should I paint the brake calipers? They'll be under the 307 wheels (on lower profile tyres so they clear everything, that's all worked out) and since they're from the 307 will fill the wheels. I'm torn between blue, red or black, possibly silver for that OEM look. I'm also torn between white and primer grey for the wheels.

Share this post


Link to post
Share on other sites
5 minutes ago, reb said:

They'll be under the 307 wheels (on lower profile tyres so they clear everything, that's all worked out) and since they're from the 307 will fill the wheels.

Test fit the wheels first - from memory, 307 wheels share the same offset as 206's which is wrong for a 205 and will sit too far inwards, fouling the rear trailing arm on the back and possibly the strut on the front.

Share this post


Link to post
Share on other sites
28 minutes ago, reb said:

Looking at the completely bare engine bay in my pride and joy definitely induced a little bit of panic because I know about my tendency to put things off and I'd rather it didn't become one of those projects that never turns a wheel again. Double panic when the extent of the mounts not fitting was realised. Fortunately I'm hung up on the desire to have something genuinely quick that I built with my own two hands, so it WILL be done as soon as reasonable!

Some good money news came immediately after I posted too, so with some careful budgeting I can do a couple of extra things I was planning on delaying a while.

 

With that in mind, what colour should I paint the brake calipers? They'll be under the 307 wheels (on lower profile tyres so they clear everything, that's all worked out) and since they're from the 307 will fill the wheels. I'm torn between blue, red or black, possibly silver for that OEM look. I'm also torn between white and primer grey for the wheels.

 

 

Leave any kind of distraction like painting. Just concentrate on the swap.

 

You’ll be cleaning the fridge next...

Share this post


Link to post
Share on other sites
22 minutes ago, Anthony said:

 

 

23 minutes ago, Anthony said:

Test fit the wheels first - from memory, 307 wheels share the same offset as 206's which is wrong for a 205 and will sit too far inwards, fouling the rear trailing arm on the back and possibly the strut on the front.

Yes, they need brought out a little bit so I need spacers, something I'm not completely happy with but needs must unfortunately as funds won't stretch to bigger wheels to clear the front brakes.

3 minutes ago, Maurice Marina said:

Leave any kind of distraction like painting. Just concentrate on the swap.

 

You’ll be cleaning the fridge next...

I won't be painting the brakes till they're going on, and the wheels will be getting farmed out to a powdercoater hopefully. Again, after the engine is in and on its way to running.

 

Funnily enough, I did actually clean the fridge on Thursday morning because flat inspection!

Share this post


Link to post
Share on other sites

By the time the belt kit arrived today the weather was a little bit too grim to really bother doing much, especially since I'll be on my own. Don't have long enough bolts to get the engine on the stand so I'll be doing the belt with it hanging from the crane with axle stands to steady it. It can wait till the morning.

20190607_181410.thumb.jpg.17e513faacaed920d29bcf5148916dd9.jpg

 

American falling in love with tiny Euro car klaxon:

20190607_174635.thumb.jpg.4e53b82a39c7d46414be519edda53163.jpg

Wonder if I can find a 1.6 auto...

Share this post


Link to post
Share on other sites

Join the conversation

You can post now and register later. If you have an account, sign in now to post with your account.
Note: Your post will require moderator approval before it will be visible.

Guest
Reply to this topic...

×   Pasted as rich text.   Paste as plain text instead

  Only 75 emoji are allowed.

×   Your link has been automatically embedded.   Display as a link instead

×   Your previous content has been restored.   Clear editor

×   You cannot paste images directly. Upload or insert images from URL.

Loading...

  • Similar Content

    • By BoggyMires
      Now in my mucky hands is this S Type Mondeo Lincoln. It's not like a Mondeo Lincoln  though, just uses some of the bits as it's from a time when jaguar was experiencing some 'technical' issues. 
      It has managed to hang onto the feel of a premium car but for the use of cost saving interior plastics made from the same gear that land Rover used in the discovery 2 of the same era, I know, I have one of those too! That has some BMW switches in it though.
       
      This jaag was cheap. Why did I buy it? All I wanted really was a small convertible for the summer to smoke around in, this is the polar opposite. 
      The price was good but these cars are without their expensive issues. I liked the body. It's virtually rust free, a freak of nature and it had a set of premium tyres on it which suggested it's had some money chucked at it.
       
      That's all I wanted really from it. The bolt on stuff and mechanicals are fairly easy to sort out, plus I can upgrade as I feel fit.
       
      Today I've been bonding with this machine. It's got to beat the 3 series I have as a good daily or it's out. It's going to be a tall order, the 318 is bionic!
       
      I have many miles to do in the next few months, I need a motorway cruiser auto. The odd jaunt for a few hundred miles is the 318's and my clutch legs limit!
       
      Now, this car has been owned previously by a few members on here, the work it requires is because it is a cheap car and 20 years old and has a jaguar badge on it. There are a few issues with it.
       
      As said, it has to be put into immediate service. I've owned it 2 days and it's already done over 300 miles, and will do all that again tomorrow! So let's get started!
       
      After about 100 miles yesterday, I reversed it for the first time in my ownership and when braking the noise was alarming! Had a look and the outer rear brake pad was metal on the disc. I only had another 60 miles to go!
      A phone call on the move saw a set in stock back home to be picked up. Sweet.
       
      That was yesterday, I've got a day now to change the rear pads and sort out the dropped headlamps with a couple of screws... A couple of hours it'll be Sorted... He says...
       
      WIND BACK CALIPERS! Yes, they are. My special tool? Sorry? What? No tool?
      Well, I cobbled together a bar and a pair of molies but Christ, that was messing about! I wanted to secure the caliper to the mounting to hold it still but the sliders internal thread was cross threaded on both sliders, so I had to tap them out first. It worked but not without a fight. Then my neighbour came over to have a nose at the new aquisition... Him: Morning, how you getting on"?, Me: "Shit, you haven't got a brake caliper tool have you"? Him: "Yeah, I'll go get it". 
       
      LIFESAVER!!!
       

       
      Sticky slider syndrome ^
       

       
      Fully padded up ^
       
      I took a look around under there, it's nearly all shot. Most ball joints are exposed to the elements so all need replacing but not before a decent jet wash.
       

       

       
      There's little play in the joints so all that goes on the list of parts and graft! Wheels on, I loosened and torqued all the wheel nuts around the car and done the Tyre pressures, we were running soft all round.
       
      Next was the front lights. A screw mod can be done but I took the back off the units and they were, well toast. Nothing much holding the inner lenses still at all. There was only one thing for it...
       

       
      I had readied myself for this. I got hold of a replacement lamp mounting kit with all parts made from nylon. This involved dissecting the lamp which was tough! The mounts that came out, or what was left of them were weaker than Jacobs crackers and just crumbled. To get the bumper off, the plastic under tray bolts were all seized so I had to grind them off. More knackered parts were seen. The auto box cooler has shed most of it's cooling fins, the radiator is sweating and the power steering is hemorrhaging fluid on full lock. There's also a coolant leak at the thermostat housing and there's a high pitch whine at 1000 RPM which turns out to be the alternator. More for the list.
      Still, back to the lights. I need to be able to see tonight so I took a level off the tourings lights and marked on to a wheely bin, these are pretty spot on. Then I can use the bin for the Jaags lights and I won't be far off 
       

       
      Going back together nicely it was a good time to run some tcut over the faded lenses. They need a more intense compound and a machine but will do for now.
       

       
      Looks smart yo!
       
      Then it got dark...
       

       
      I then drove 120 miles in it and drove it like it was stolen. It had it, all of it! Slight brake judder at 90 and I couldn't get the alignment done as I had no time (see above pics)
       
      So now we have to price up priorities like the knackered joints on the rear and a full service, two Goodyears and investigate the power steering leak which, I'll hazard a guess at the rack seals are fubard. 
       
      So in summary, I got a bargain barge that has it's fair share of issues, the interior quality is a bit shocking in places but when the hammer is down, none of this matters! It fits in, it can be a proper giffer cruiser with radio two on at 30mph but it'll turn into a bruiser with some oldskool hardcore at a tonne. It's come to a good home.
    • By reb
      I have an increasingly rare night off tonight, so I went out to have a prod around the 205 to remind myself what needs doing. It stills amazes me how utterly rust free it is, certainly the bits I can get at with it on the ground anyway. Minor grump about discovering the rear drivers side wheel has been rubbing on the inside, but I'll see to that in time.

      There's not much else to say right now, so have a photo of it before it was off the road!

      And another!

    • By davehedgehog31
      I've had various threads on the go for different collections this year, but thought I'd condense my threads into one manageable thread to document my ham-fisted tinkering.

      At the turn of the year I was driving a nice, dependable, modern 2011 Peugeot 407 and no other vehicle. It was nice enough, but boring as feck. I'd bought it after a series of disastrous heaps in the awkward age bracket of being new and valuable enough to worry about but old enough to be fucked. The 407 was just too new, too bloated and dull. I had a hankering for old metal, my Mineral Oil withdrawal pangs were strong.

      From January I started looking, there were eBay bids, missed reserves, wasted trips from Gumtree and other such nonsense. I happened on an automatic Rover 216 GSI with one giffer owner from a year old. The chap was giving up driving at 93 years old and his grandson was moving it on. I bid, and failed. It was in London though, about 420 miles away so I wasn't all that bothered. Of course when he offered it to me for my losing bid after the winning buyer was a no show I said yes. I was on the Megabus down to that London overnight for about £15. I hung about in Liverpool Street station like a mad shivering jakey until my train out to the suburb for my first sight of the new steed. It was battered outside but had been well looked after. A frankly insulting amount of cash changed hands and I was away up the road.

      We had many adventures together, it was dependable and it whet my appetite for interesting old motors again and proved that the very bottom end of the market was navigable if I had the patience to wade through the sea of shit to find the odd pearl.



      The 407 was still on the fleet at this point but I was covering a lot of miles in the Rover, with a long commute though the fuel economy wasn't ideal. When a friend's mother was looking for a new diesel saloon to replace the faithful old Xsara she had a scheme was concocted. I sold the 407 to her and was on the hunt for an interesting replacement.

      When I was growing up my dad had a succession of hopeless shitters, indeed I was brought home from the hospital as a newborn in a brush painted Skoda Super Estelle. The best car he had was a red XUD Peugeot 405 with air conditioning and electric windows. So when I found a 1994 GTXD advertised by someone who could actually compose a car advert in the fashion you would expect of a human being educated to a Primary School level, I pounced.

      Of course I couldn't buy a car just down the road so it was on the train to Birmingham. First class no less. I stayed in an absolute flea pit of a hotel and drove up the road the next day. This was a proper bit of nostalgia and a really practical borderline classic car. It had been fastidiously maintained by the previous owner. Apart from there being a hole where there was once a stereo and the lack of working air con it was a pleasant drive home.

      Given their relative scarcity and how dependable this one has proven so far, it's a keeper, I'd struggle to part with it.



      Two cars just wasn't enough to worry about, so this Citroen C1 was acquired. Pure Aleppo spec. A camel can go for weeks, or months without stopping at a watering hole, the C1 has a similar thirst for Motor Spirit. Man maths were employed and worked out that it would easily* pay for itself.




      There have been further movements, I'll recap them shortly. I should probably do some work.
×
×
  • Create New...