1991 Peugot 309 2.1td conversion
Discussion
So it was all going so well today 😄
Started off with the last couple of things before dropping the engine in.
As standard, these engines run 15psi of boost.
On the inlet fanimould, is these rubber connectors that link to another part of the inlet.
And they are simply a push fit.
So i added jubilee clips to stop any boost leaks.
Then fitted the EGR blanking plate that my mate helped me make the other day
Then dropped the engine onto the skate and got it round, ready to fit the gear box
I swapped the rad hoses and realised how bad the original one was!
The 2.1 lump is 12v, the 1.8 8v, so there's a space issue with the head donking the servo, so to get round this, you need to move the left hand engine mount forward a tad.
A few washers behind one, and cutting off 15mm off the other does just the job
[url
|https://thumbsnap.com/DyoHJWgS[/url]
Then I fitted the half shaft and removed and cleaned the seal
[url
|https://thumbsnap.com/b1AeX3ek[/url]
Then I hit a problem.
I'd planned to use all the boost pipework that was on the 2.1 along with the intercooler.
So I tried to fit the pipe that goes under the engine to the IC and it wouldn't fit.
Turns out the 2.1 halfshaft sits higher, allowing the clearance requited. Ffs
Now to work out how to make this work.
I've only got the engine crane on loan for another couple of weeks too :/
All was going so well!
Started off with the last couple of things before dropping the engine in.
As standard, these engines run 15psi of boost.
On the inlet fanimould, is these rubber connectors that link to another part of the inlet.
And they are simply a push fit.
So i added jubilee clips to stop any boost leaks.
Then fitted the EGR blanking plate that my mate helped me make the other day
Then dropped the engine onto the skate and got it round, ready to fit the gear box
I swapped the rad hoses and realised how bad the original one was!
The 2.1 lump is 12v, the 1.8 8v, so there's a space issue with the head donking the servo, so to get round this, you need to move the left hand engine mount forward a tad.
A few washers behind one, and cutting off 15mm off the other does just the job
[url
|https://thumbsnap.com/DyoHJWgS[/url]Then I fitted the half shaft and removed and cleaned the seal
[url
|https://thumbsnap.com/b1AeX3ek[/url]Then I hit a problem.
I'd planned to use all the boost pipework that was on the 2.1 along with the intercooler.
So I tried to fit the pipe that goes under the engine to the IC and it wouldn't fit.
Turns out the 2.1 halfshaft sits higher, allowing the clearance requited. Ffs
Now to work out how to make this work.
I've only got the engine crane on loan for another couple of weeks too :/
All was going so well!
bearman68 said:
The photo location in the first post looks like Blaenau Ffestiniog in North Wales. Big piles of slate piled everywhere.
I'm running a 1.9 XUD in a Citroen ZX at the moment. No turbo. Painfully slow might be overegging it a bit, but it's certainly not fast.
It is indeed! Was such a good trip there.I'm running a 1.9 XUD in a Citroen ZX at the moment. No turbo. Painfully slow might be overegging it a bit, but it's certainly not fast.
Even with the car loaded up for a weeks camping and the slowest engine known to man, the Welsh roads were awesome!
You must have a goodun! Mine needed first gear up certain hills!
ishanolee said:
Master Of Puppets said:
Great thread, will keep a watch on this. Reminds me of 20 odd years ago when 309 GTi's could be bought for a few hundred quid
we had one with a blown engine and decided to convert it to a DTurbo from a BX, it was an easy swap and was a great daily runner, all
the looks of the GTi with superb economy and reliability, word got round and we ended up doing half a dozen of them, all were 3 door,
one was a Goodwood and another was the rare Miami blue version with the blue chequered seats and carpet.
Seems like a waste when you look at the prices of them now but back then they were readily available and cheap.
I bought a red 3 door K reg GTi which had been converted to 1.9TD from Stockport around 2006. Must of been one of yours.we had one with a blown engine and decided to convert it to a DTurbo from a BX, it was an easy swap and was a great daily runner, all
the looks of the GTi with superb economy and reliability, word got round and we ended up doing half a dozen of them, all were 3 door,
one was a Goodwood and another was the rare Miami blue version with the blue chequered seats and carpet.
Seems like a waste when you look at the prices of them now but back then they were readily available and cheap.
the 205 STDT but with a better interior than the horrid beige dash they used to come with.
OP... What is the EG?. JDM tailgate so assuming SiR?
Master Of Puppets said:
ishanolee said:
Master Of Puppets said:
Great thread, will keep a watch on this. Reminds me of 20 odd years ago when 309 GTi's could be bought for a few hundred quid
we had one with a blown engine and decided to convert it to a DTurbo from a BX, it was an easy swap and was a great daily runner, all
the looks of the GTi with superb economy and reliability, word got round and we ended up doing half a dozen of them, all were 3 door,
one was a Goodwood and another was the rare Miami blue version with the blue chequered seats and carpet.
Seems like a waste when you look at the prices of them now but back then they were readily available and cheap.
I bought a red 3 door K reg GTi which had been converted to 1.9TD from Stockport around 2006. Must of been one of yours.we had one with a blown engine and decided to convert it to a DTurbo from a BX, it was an easy swap and was a great daily runner, all
the looks of the GTi with superb economy and reliability, word got round and we ended up doing half a dozen of them, all were 3 door,
one was a Goodwood and another was the rare Miami blue version with the blue chequered seats and carpet.
Seems like a waste when you look at the prices of them now but back then they were readily available and cheap.
the 205 STDT but with a better interior than the horrid beige dash they used to come with.
OP... What is the EG?. JDM tailgate so assuming SiR?
Well, was. Ha.
It's B16 turbo now. EK9 head and cams, fully forged. 400whp.
105.4 said:
Good news…. I’ve got one you can borrow.
Bad news….. I’m up in North Derbyshire.
The option’s there if you need it
Ha! Thanks for the offer but you're miiiiiiiiles away!Bad news….. I’m up in North Derbyshire.
The option’s there if you need it
I'm going to try and heat the plastic pipework up this weekend and shape it, so hopefully that works.
If not, I'll get some silicone couplers and route the pipework over the gearbox.
There is hope 😄
So more progress today!
After the issue with the boost pipe and half shaft, I ordered a 135 degree silicone bend.
But unfortunately not only did it not fit without a horrific bend, it also blocked the speedo drive on the gear box...
So I racked my brain about how to make it work.
And with a heat gun, and lots of gentle persuasion, squished the original boost pipe enough to give it about 8mm of clearance on the shaft.
Winner!
Then, before dropping the engine in, fitted a short shift.
I'm not sure if when set to the shortest shift, the syncros will have time to slow down enough, but I'll soon find out if it crunches between gears. Ha!
Then finally got to drop it in!
And then swore.
Lots.
And figured why this conversion isn't common.
Although it 'in', its not sitting on the engine mounts yet.
I can't figure out why I can't get the engine back far enough.
I've had to move and bend one of the metal water lines out the way and also realised that the original mount didn't fit.
After a couple of hours faffing around, I recovered the old cam belt covers from the dustbin (thank f
k I forgot to put my bins out twice) and realised that they have a notch cut out.
So hopefully, tomorrow I can cut the same notch out and get it all in properly!
But, I'm now seeing why no one does this conversion and am certain it won't go well.
Definitely regretting starting this now!
After the issue with the boost pipe and half shaft, I ordered a 135 degree silicone bend.
But unfortunately not only did it not fit without a horrific bend, it also blocked the speedo drive on the gear box...
So I racked my brain about how to make it work.
And with a heat gun, and lots of gentle persuasion, squished the original boost pipe enough to give it about 8mm of clearance on the shaft.
Winner!
Then, before dropping the engine in, fitted a short shift.
I'm not sure if when set to the shortest shift, the syncros will have time to slow down enough, but I'll soon find out if it crunches between gears. Ha!
Then finally got to drop it in!
And then swore.
Lots.
And figured why this conversion isn't common.
Although it 'in', its not sitting on the engine mounts yet.
I can't figure out why I can't get the engine back far enough.
I've had to move and bend one of the metal water lines out the way and also realised that the original mount didn't fit.
After a couple of hours faffing around, I recovered the old cam belt covers from the dustbin (thank f
k I forgot to put my bins out twice) and realised that they have a notch cut out.So hopefully, tomorrow I can cut the same notch out and get it all in properly!
But, I'm now seeing why no one does this conversion and am certain it won't go well.
Definitely regretting starting this now!
Edited by Lawbags on Saturday 6th January 17:56
Great work!
Be thankful, our first family car was a 205 GRD, with XUD7, which used to get out dragged by Commercial vehicles, still it just needed more commitment through the bends to get the overtake done on the next straight
Probably the surprising part about this whole thread was the fact that there was a Xantia left?
Be thankful, our first family car was a 205 GRD, with XUD7, which used to get out dragged by Commercial vehicles, still it just needed more commitment through the bends to get the overtake done on the next straight
Probably the surprising part about this whole thread was the fact that there was a Xantia left?
Lawbags said:
Well, thats the end.
Turns out the XUD11 engine has a topmount turbo which means it won't fit.
Options are to bash the hell out of the firewall with a hammer or remote mount the turbo ontop of the gear box.
Neither which I really want to do
would an XUD9TE manifold fit the head to relocate the turbo?Turns out the XUD11 engine has a topmount turbo which means it won't fit.
Options are to bash the hell out of the firewall with a hammer or remote mount the turbo ontop of the gear box.
Neither which I really want to do
Lawbags said:
Well, thats the end.
Turns out the XUD11 engine has a topmount turbo which means it won't fit.
Options are to bash the hell out of the firewall with a hammer or remote mount the turbo ontop of the gear box.
Neither which I really want to do
Don't be daft - you're FAR too far into this to give up now! Look at the work you've done. Turns out the XUD11 engine has a topmount turbo which means it won't fit.
Options are to bash the hell out of the firewall with a hammer or remote mount the turbo ontop of the gear box.
Neither which I really want to do
What are you going to do - scrap it? Of course you aren't. Have a cup of tea/cold beer, do something else for a few days, then come back to this with a clear head. And give us all a really detailed update on how you've solved the turbo problem. I'll be waiting for it.
Lawbags said:
Mr Happy said:
would an XUD9TE manifold fit the head to relocate the turbo?
That was what I wondered.Turns out the ports are totally different!
I don't think you'd be able to invert the existing turbo manifold either.
Did they do an NA variant of the XUD11? if so the NA manifold might be easier to hack up for a turbo as it'll already be dropping into the right area.
Mr Happy said:
Bugger!
I don't think you'd be able to invert the existing turbo manifold either.
Did they do an NA variant of the XUD11? if so the NA manifold might be easier to hack up for a turbo as it'll already be dropping into the right area.
Nope. Unfortunately there's nothing suited except relocating the turbo ontop of the gear box.I don't think you'd be able to invert the existing turbo manifold either.
Did they do an NA variant of the XUD11? if so the NA manifold might be easier to hack up for a turbo as it'll already be dropping into the right area.
Slight update!
I phoned around some places to get prices on a turbo relocation pipe and downpipe/exhaust and was such high prices (around a grand) I wrote the project off.
I decided to scrap this idea and go with the XUD9 turbo.
A common conversion from the 306.
So I tried to find a lowish milage engine and couldn't find one.
Nor an XUD7te, the 1.8turbo that came in the 309/205.
This was supposed to be a cheap project, so an e engine rebuild was definitely out.
So back to the drawing board.
I thought I'd phone the place that ive used for years for exhausts back where I used to live for a price on the exhaust etc.
Half what I was quoted in Wiltshire!
So decided the only option was to stick with it.
I still needed to get the lump in properly, so had to remove the turbo.
But as per everything with this, it wasnt that simple.
Exhaust fanimould had to come off and instead of the obvious 3 bolts on the turbo flange, Citroen used 2 normal bolts and one Allen bolt, that obviously rounded off.
So out came the mangle grinder.
Once off, I refitted the mani and hoped to hell the engine would fit.
Which it did.
Although I spaces the drivers side mount forward, space is still verrrrrrry tight, so I've ordered some polyurethane to make my own mount to push it further forward
You can see how close it is here
And how much I've already had to move the mount forward
So that's hopefully the hard work done now.
Need some nicer weather to hurry up. Getting fed up of working in the rain and dark!!
I phoned around some places to get prices on a turbo relocation pipe and downpipe/exhaust and was such high prices (around a grand) I wrote the project off.
I decided to scrap this idea and go with the XUD9 turbo.
A common conversion from the 306.
So I tried to find a lowish milage engine and couldn't find one.
Nor an XUD7te, the 1.8turbo that came in the 309/205.
This was supposed to be a cheap project, so an e engine rebuild was definitely out.
So back to the drawing board.
I thought I'd phone the place that ive used for years for exhausts back where I used to live for a price on the exhaust etc.
Half what I was quoted in Wiltshire!
So decided the only option was to stick with it.
I still needed to get the lump in properly, so had to remove the turbo.
But as per everything with this, it wasnt that simple.
Exhaust fanimould had to come off and instead of the obvious 3 bolts on the turbo flange, Citroen used 2 normal bolts and one Allen bolt, that obviously rounded off.
So out came the mangle grinder.
Once off, I refitted the mani and hoped to hell the engine would fit.
Which it did.
Although I spaces the drivers side mount forward, space is still verrrrrrry tight, so I've ordered some polyurethane to make my own mount to push it further forward
You can see how close it is here
And how much I've already had to move the mount forward
So that's hopefully the hard work done now.
Need some nicer weather to hurry up. Getting fed up of working in the rain and dark!!
Edited by Lawbags on Thursday 18th January 06:23
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