1991 Peugot 309 2.1td conversion
Discussion
Was the fitting issue that the turbo turbine outlet was so high up that the exhaust wouldn’t fit up through the space available?
Assuming you’re now getting the down pipe made up to reach up to the higher located turbo?
I remember my brother getting 132bhp on his 1.9Td on Bosch pump and k03 turbo but it was quite laggy and revving up at 4500rpm to make the power, all a bit silly, but lots of fun. But economy was probably terrible too.
A 2.1Td done right will probably be a lot more giggle inducing in a diesel kinda way, especially in a 309, so kudos!
I’m excited to see it finished and a report on what it’s like!
Assuming you’re now getting the down pipe made up to reach up to the higher located turbo?
I remember my brother getting 132bhp on his 1.9Td on Bosch pump and k03 turbo but it was quite laggy and revving up at 4500rpm to make the power, all a bit silly, but lots of fun. But economy was probably terrible too.
A 2.1Td done right will probably be a lot more giggle inducing in a diesel kinda way, especially in a 309, so kudos!
I’m excited to see it finished and a report on what it’s like!
Mr Whippy said:
Was the fitting issue that the turbo turbine outlet was so high up that the exhaust wouldn’t fit up through the space available?
Assuming you’re now getting the down pipe made up to reach up to the higher located turbo?
I remember my brother getting 132bhp on his 1.9Td on Bosch pump and k03 turbo but it was quite laggy and revving up at 4500rpm to make the power, all a bit silly, but lots of fun. But economy was probably terrible too.
A 2.1Td done right will probably be a lot more giggle inducing in a diesel kinda way, especially in a 309, so kudos!
I’m excited to see it finished and a report on what it’s like!
Yeah, the turbo on all other XUDs sits underneath the fanimound.Assuming you’re now getting the down pipe made up to reach up to the higher located turbo?
I remember my brother getting 132bhp on his 1.9Td on Bosch pump and k03 turbo but it was quite laggy and revving up at 4500rpm to make the power, all a bit silly, but lots of fun. But economy was probably terrible too.
A 2.1Td done right will probably be a lot more giggle inducing in a diesel kinda way, especially in a 309, so kudos!
I’m excited to see it finished and a report on what it’s like!
On the 11, it sits straight out the back or on the top.
You can smash the hell outta the firewall and tunel to make it fit, but you need a good 2" slot bashed into it.
And yeah, these engines are bomb proof. With this turbo and pump it can run 160 easy.
The turbo cold side can be loosened slightly which will allow the cold side outlet to be rotated, which may help with the pipework clearance.
There used to be a few Pug 205 converted with the 2.1 TD. Have you had a look on 205gtidrivers.com that is still a fairly active forum and there are some old threads from people who have done the conversion. It looks like most cut and weld the bulkhead to get clarence for it to fit or relocate the turbo if they're looking at fitting a larger one.
I have a 205 with a 1.9 TD conversion, but I'm now looking to go the other way and convert it to a petrol even though it will probably end up being slightly slower. I may have the 1.9TD engine available if you are interested, but personally I would stick to the 2.1 now you have it.
This is a link to a dutch guy with how he did his conversion, hope it helps.
https://www.205gti.com/story_rudy_tdiNL.htm
Good luck.
There used to be a few Pug 205 converted with the 2.1 TD. Have you had a look on 205gtidrivers.com that is still a fairly active forum and there are some old threads from people who have done the conversion. It looks like most cut and weld the bulkhead to get clarence for it to fit or relocate the turbo if they're looking at fitting a larger one.
I have a 205 with a 1.9 TD conversion, but I'm now looking to go the other way and convert it to a petrol even though it will probably end up being slightly slower. I may have the 1.9TD engine available if you are interested, but personally I would stick to the 2.1 now you have it.
This is a link to a dutch guy with how he did his conversion, hope it helps.
https://www.205gti.com/story_rudy_tdiNL.htm
Good luck.
xstian said:
The turbo cold side can be loosened slightly which will allow the cold side outlet to be rotated, which may help with the pipework clearance.
There used to be a few Pug 205 converted with the 2.1 TD. Have you had a look on 205gtidrivers.com that is still a fairly active forum and there are some old threads from people who have done the conversion. It looks like most cut and weld the bulkhead to get clarence for it to fit or relocate the turbo if they're looking at fitting a larger one.
I have a 205 with a 1.9 TD conversion, but I'm now looking to go the other way and convert it to a petrol even though it will probably end up being slightly slower. I may have the 1.9TD engine available if you are interested, but personally I would stick to the 2.1 now you have it.
This is a link to a dutch guy with how he did his conversion, hope it helps.
https://www.205gti.com/story_rudy_tdiNL.htm
Good luck.
The pipework clearance isn't an issue anymore.There used to be a few Pug 205 converted with the 2.1 TD. Have you had a look on 205gtidrivers.com that is still a fairly active forum and there are some old threads from people who have done the conversion. It looks like most cut and weld the bulkhead to get clarence for it to fit or relocate the turbo if they're looking at fitting a larger one.
I have a 205 with a 1.9 TD conversion, but I'm now looking to go the other way and convert it to a petrol even though it will probably end up being slightly slower. I may have the 1.9TD engine available if you are interested, but personally I would stick to the 2.1 now you have it.
This is a link to a dutch guy with how he did his conversion, hope it helps.
https://www.205gti.com/story_rudy_tdiNL.htm
Good luck.
Now that the turbos being relocated!
And yeah, I hammered the forums and bookface pages to find the solution. Luckily someone whs done the conversion in a 306 had heaps of pics and couldn't help enough!
And thanks, but I've decided to stick with it now!
So where are you going with the turbo?
I know lots of 306s etc went with turbo over gearbox and battery in boot iirc?
Seems like a well trodden route so worth going the same way!
I occasionally look at 306s again thinking how cool an old GTi6 or HDi (with tweaks) would be… but cripes the prices!
It’s interesting also how unlike many similar age cars like Fords etc, Peugeots have remained largely rust free.
It’s all the annoying jobs that are labour intensive (for people paying garages) that puts them off the road, like seized rear suspension beams etc.
I’m now looking to see if anyone put T16 bits in a 309
I know lots of 306s etc went with turbo over gearbox and battery in boot iirc?
Seems like a well trodden route so worth going the same way!
I occasionally look at 306s again thinking how cool an old GTi6 or HDi (with tweaks) would be… but cripes the prices!
It’s interesting also how unlike many similar age cars like Fords etc, Peugeots have remained largely rust free.
It’s all the annoying jobs that are labour intensive (for people paying garages) that puts them off the road, like seized rear suspension beams etc.
I’m now looking to see if anyone put T16 bits in a 309
Mr Whippy said:
So where are you going with the turbo?
I know lots of 306s etc went with turbo over gearbox and battery in boot iirc?
Seems like a well trodden route so worth going the same way!
I occasionally look at 306s again thinking how cool an old GTi6 or HDi (with tweaks) would be… but cripes the prices!
It’s interesting also how unlike many similar age cars like Fords etc, Peugeots have remained largely rust free.
It’s all the annoying jobs that are labour intensive (for people paying garages) that puts them off the road, like seized rear suspension beams etc.
I’m now looking to see if anyone put T16 bits in a 309
Yeah, mounting it above the gear box and battery in the boot.I know lots of 306s etc went with turbo over gearbox and battery in boot iirc?
Seems like a well trodden route so worth going the same way!
I occasionally look at 306s again thinking how cool an old GTi6 or HDi (with tweaks) would be… but cripes the prices!
It’s interesting also how unlike many similar age cars like Fords etc, Peugeots have remained largely rust free.
It’s all the annoying jobs that are labour intensive (for people paying garages) that puts them off the road, like seized rear suspension beams etc.
I’m now looking to see if anyone put T16 bits in a 309
They do rust a bit, but mine is in incredible condition.
None of the usual areas have any rust at all!
Finally a bit of progress.
This engine is 12valve and the previous engine 8.
So the head is wider, meaning it interferes with the servo.
I'd already forced it forward ad much as I could using the existing mounts by adding washers behind the rear mount, but it wasn't enough.
So I got the lump if polyurethane and made my own mount.
I drilled a hole in one side and hammered a nut into it, so I could wind a bolt into it, through the existing hole that the OEM mount uses
I wedged it in, then it took me absolutely ages to line it up.
A tiny bit at a time and I finally got it and bolted it up.
But unfortunately, it still wasn't enough.
So I cut and hammered a second bit of polyurethane in to force the engine sideways a tad.
Then had the problem of how to stop it popping out again, so buzzed a couple of hole in and a couple of nuts and bolts later, and problem solved.
If I'd have known this, while the engine was out, I've had drilled a hole in the middle, so I could hammer a nut into it and do the same as the other mount, but oh well, it'll work.
I also fitted the turbo rad and fans the other day and refitted some of the wiring.
After ringing round alomost every fabricator i couls find, I finally found someone local to laser cut me the flanges to relocate the turbo.
And they also may be able to give me a good price to make the exhaust and turbo relocation pipe.
Be a result as it'd save me towing the car to my mate, 2 hours away!
More to do tomorrow
This engine is 12valve and the previous engine 8.
So the head is wider, meaning it interferes with the servo.
I'd already forced it forward ad much as I could using the existing mounts by adding washers behind the rear mount, but it wasn't enough.
So I got the lump if polyurethane and made my own mount.
I drilled a hole in one side and hammered a nut into it, so I could wind a bolt into it, through the existing hole that the OEM mount uses
I wedged it in, then it took me absolutely ages to line it up.
A tiny bit at a time and I finally got it and bolted it up.
But unfortunately, it still wasn't enough.
So I cut and hammered a second bit of polyurethane in to force the engine sideways a tad.
Then had the problem of how to stop it popping out again, so buzzed a couple of hole in and a couple of nuts and bolts later, and problem solved.
If I'd have known this, while the engine was out, I've had drilled a hole in the middle, so I could hammer a nut into it and do the same as the other mount, but oh well, it'll work.
I also fitted the turbo rad and fans the other day and refitted some of the wiring.
After ringing round alomost every fabricator i couls find, I finally found someone local to laser cut me the flanges to relocate the turbo.
And they also may be able to give me a good price to make the exhaust and turbo relocation pipe.
Be a result as it'd save me towing the car to my mate, 2 hours away!
More to do tomorrow
Edited by Lawbags on Saturday 10th February 18:28
Edited by Lawbags on Saturday 10th February 18:29
Edited by Lawbags on Saturday 10th February 18:30
DanG355 said:
Glad the project has not been abandoned. It’s a good read and a real ‘people’s hero’ car.
Absolutely !This is the first time I’ve been back to this thread since very early January and I was gutted to read that you’d almost given up on this.
As for working outside in the cold, the dark, and the rain, I can only assume that you must have got a screw lose
Spinakerr said:
Loving this project, 309 is a fantastic shape. My great uncle had the Goodwood green GTI - keen to see how this turns out!
I had one of those, (although I’m not your Uncle).A K reg 5 door, adjustable Koni’s, head and cam by LAD, 306 GTI-6 brakes, stainless manifold and exhaust, fully poly-bushed, etc, etc.
Like an idiot I sold it for a Golf VR6 Highline and regretted it ever since
105.4 said:
DanG355 said:
Glad the project has not been abandoned. It’s a good read and a real ‘people’s hero’ car.
Absolutely !This is the first time I’ve been back to this thread since very early January and I was gutted to read that you’d almost given up on this.
As for working outside in the cold, the dark, and the rain, I can only assume that you must have got a screw lose
I've been a bit disheartened about it, but definitely have the bug back again
Finally payday has come and more bits bought and more progress made.
Started off swapping the well corroded water pipe with a stainless one and one of the very perished hoses was replaced with a new one.
But of course, like everything with this, it wasnt straight forward.
The hose that was definitely, 100% for certain going to fit, didn't.
So I had to chop up the rubber hose from the Xantia, which ran from the rear, right to the rad and use a piece of that.
Then I visited a guy not far away who's got a w
k worthy amount of 309 and 205 spares to get some needle rollers after loosing a couple.
I cleaned, greased and loaded them up before dropping the ring on.
This is something I definitely don't ever want to do again.
Then refitted the shaft.
I'd also ordered an intercooler.
I went to offer it up and realised that it won't fit.
Wonderful.
So back to the drawing board on that.
As I'm not running the diseasel heater, one of the hoses was too short to reach the filter.
Typically the spring clip that held it onto the solid lines had spun around so the legs were touching the fire wall.
I spent ages trying to get it off without luck, so gave up and just extended it a tad.
I swapped one of the solid lines from the old pump and checked the banjo bolts while at it to find that one of them had some solid gunk in the pin hole, so cleaned that out before refitting.
Then connected up all the fuel hoses to the pump.
Something actually went without am issue!!!
As the turbo is going to sit on the gear box, I have to move the battery to the boot.
I ordered 0 gauge cable and terminals.
And then found the terminals are miles too big.
That's it for the mo.
More to follow soon hopefully!
Started off swapping the well corroded water pipe with a stainless one and one of the very perished hoses was replaced with a new one.
But of course, like everything with this, it wasnt straight forward.
The hose that was definitely, 100% for certain going to fit, didn't.
So I had to chop up the rubber hose from the Xantia, which ran from the rear, right to the rad and use a piece of that.
Then I visited a guy not far away who's got a w
k worthy amount of 309 and 205 spares to get some needle rollers after loosing a couple.I cleaned, greased and loaded them up before dropping the ring on.
This is something I definitely don't ever want to do again.
Then refitted the shaft.
I'd also ordered an intercooler.
I went to offer it up and realised that it won't fit.
Wonderful.
So back to the drawing board on that.
As I'm not running the diseasel heater, one of the hoses was too short to reach the filter.
Typically the spring clip that held it onto the solid lines had spun around so the legs were touching the fire wall.
I spent ages trying to get it off without luck, so gave up and just extended it a tad.
I swapped one of the solid lines from the old pump and checked the banjo bolts while at it to find that one of them had some solid gunk in the pin hole, so cleaned that out before refitting.
Then connected up all the fuel hoses to the pump.
Something actually went without am issue!!!
As the turbo is going to sit on the gear box, I have to move the battery to the boot.
I ordered 0 gauge cable and terminals.
And then found the terminals are miles too big.
That's it for the mo.
More to follow soon hopefully!
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