Tales from beyond the grave AKA Dan & Emma's Black Xantia, pug 206HDi, Daniel's 206 Verve 1.4i, GTi180 plus XUD9TE 206!!

Tell us your ongoing tales and experiences with your French car here. Post pictures of your car here as well.

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ekjdm14
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Re: Tales from beyond the grave AKA Dan & Emma's Black Xantia, pug 206HDi, Daniel's 206 Verve 1.4i... Oh, & a GTi180

Post by ekjdm14 »

Oh, thought I'd replied to the above post. Sorry for the delay! The blue 206 has gone on a hiatus for the moment, mainly lack of motivation to do welding for now although that's ironic because the next thing I jumped on with required none other than... lovely welding!

That "next thing" happens to be Black, the car that started it all with this thread. She's now back on the road as of today, after standing for 2 years all she required for the MoT was the exhaust, wheel bearing and door jamb patch that I already knew needed attending to. Advisories just pertaining to a little perishing to the 2 tyres that had been facing the sun during her rest period. Faithful old girl fired up with nary a stutter or miss after waiting so long for her return to glory, and this business going on at the moment gave me a perfect excuse to spend some time playing & getting her ready again.

In truth, she'd have been on the road weeks ago except for the fact that we couldn't book an MoT until local garages had decided how they were going to handle the safety aspect of things. But, MoT passed today and we're off to do our essential shopping once a day in comfort and luxury. God alone knows when I'll get back on here, hopefully sooner than later. Stay safe all, here's to good health.

ekjdm14
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Re: Tales from beyond the grave AKA Dan & Emma's Black Xantia, pug 206HDi, Daniel's 206 Verve 1.4i... Oh, & a GTi180

Post by ekjdm14 »

Black has been very pleased about her return to the road, even though we can't reasonably go for a good long run out yet it's a lovely contrast to the 180. (Contrast? It's the polar opposite in nearly every way!!!) The comfy, smooth, quiet and wafty drive is so good.

ekjdm14
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Re: Tales from beyond the grave AKA Dan & Emma's Black Xantia, pug 206HDi, Daniel's 206 Verve 1.4i... Oh, & a GTi180

Post by ekjdm14 »

Eldest lad has just dragged back another 206!!! (Well, it was delivered).

1.1 S in metallic black, MoT till September with receipts for recent rear beam, discs/pads, 4 tyres (on BSA 15" alloys), cat-back exhaust, battery and a few other bits. Bought for £450 delivered from B'ham as a non-runner, it arrived missing it's BSM :? :roll: :rofl2: so little wonder it didn't run! Just slapped in the old spare one from the missus' HDi and it fired up and runs really nicely...

It's a gamble that's paid off for him really since he was happy to pay the price for the tidy rolling shell, in the colour he wanted, delivered to our door. His intention is to XUD-Turbo swap it after having seen another heavily modded 206 locally with that engine, so being a run/drive is just a bonus as far as he's concerned & he now has some more bits to sell to fund the derv transplant.

The drivetrain I'm thinking of putting together in this is (loosely) going to be either a 1.9 or 2.1 TD long block, possibly some head work (the engine, not mine. Although some would recommend it I think!), cam either NA-D or reprofiled TD, homebrew steel exhaust manifold routed to site the (uprated) turbo atop the gearbox & exhaust to run back from there, front-mount intercooler, obviously Bosch pump with LDA reprofiling, some kind of auto-spec radiator (one with a trans-oil cooler, to be repurposed as fuel heater as intend to be 100% veg ready), gearbox unsure as yet but likely start off with a standard 2.0HDi manual unit & work from there. Brakes will have to be attended to also, not sure what route as yet but GTi180 are a bit obvious so will look into what setups other larger engined 206's use.

Above list as much for my records/memory as anything else, it's going to be fun if nothing else!

lexi
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Re: Tales from beyond the grave AKA Dan & Emma's Black Xantia, pug 206HDi, Daniel's 206 Verve 1.4i... Oh, & a GTi180

Post by lexi »

It's good to see a whole family carry on the Craft of spannering!

moizeau
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Re: Tales from beyond the grave AKA Dan & Emma's Black Xantia, pug 206HDi, Daniel's 206 Verve 1.4i... Oh, & a GTi180

Post by moizeau »

Then banger race it Dan

ekjdm14
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Re: Tales from beyond the grave AKA Dan & Emma's Black Xantia, pug 206HDi, Daniel's 206 Verve 1.4i... Oh, & a GTi180

Post by ekjdm14 »

Haha I've seen a 206 banger raced, unsurprisingly the rear beam was the reason for it's retirement!

1.1 engine is out, it's nice to have an apprentice to help out & even Ryan our younger lad has been getting in on the tool-passing!

ekjdm14
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Re: Tales from beyond the grave AKA Dan & Emma's Black Xantia, pug 206HDi, Daniel's 206 Verve 1.4i... Oh, & a GTi180

Post by ekjdm14 »

We have our 1.9TD lump, test fired it the other day (after blowing out the years of cobwebs and plant matter from the intake ports!) and the basis seems sound. Turbo may or may not be oily (could've been seepage from laying on it's back on the way home) but no real concern as we're not using a tiny standard one. Pump may have contamination issues as had no throttle control and would only run while pumping the primer, didn't appear to be lifting fuel for itself, but I have another VE here I'm planning to reseal for veg & do some tweaking so the other one will be handy as an unmodded reference/parts if we get too smokey in our endeavours.

Gearbox-wise, we've possibly got a complete 2.0HDi (might even be 2.2, dunno) engine/box ex-406 for a cool £30 collecting tomorrow. Will have to do some jiggery-pokery with driveshafts but hoping either the whole inner joints from a DW8 206 will fit (or possibly just the tripod bearing into the 406 cups). Still have to work out what we're doing about an intake manifold and some serious chopping/welding to the exhaust manifold, namely chopping the flange off & making a steel tubular jobbie to relocate the turbo.

If the HDi lump itself seems to be healthy (will try and crank it over at least, maybe get it to run off a spray bottle for a second) then that'll go back up for sale to help fund the project driveshafts and conversion to hydraulic clutch.

Anyway, long drive to Derbyshire ahead tomorrow so best get some kip.

ekjdm14
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Re: Tales from beyond the grave AKA Dan & Emma's Black Xantia, pug 206HDi, Daniel's 206 Verve 1.4i... Oh, & a GTi180

Post by ekjdm14 »

Gearbox and "freebie" engine now at home, shattered now though as it was HOT today!!! Hopefully will have recovered enough tomorrow to throw it on the end of the XUD & do a dry-run dropping it in the bay to help measuring and working out driveshafts/linkages/turbo location etc.

Not sure if I'll be able to make something work with the gear linkages or if I'll have to convert to cable shift, but having a gearbox here to allow test-fitting and working out is the important thing. As far as the clutch goes, I may look at modifying (extending) the release arm to take a cable and at the same time go over to a push type pressure plate.

Another thing I'll consider more when I've measured it, is possibly using the intake manifold from the HDi if it fits the XUD head (only because it came with the HDi and we need one, otherwise I'd want to probably stay with the XUD intake & plenum setup as it's nice and tough for boost.

ekjdm14
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Re: Tales from beyond the grave AKA Dan & Emma's Black Xantia, pug 206HDi, Daniel's 206 Verve 1.4i, GTi180 plus XUD9TE 2

Post by ekjdm14 »

Today, a down-at-heel 2000 206 GTi followed us home!!!

It's a tatty old motor, dinged up shell with corrosion and at least 170k last year when the odometer worked. £300 would normally be a bit excessive for such a tired car but this has the benefit of GTi180 alloys with 4 new Uniroyal's, lots of the trim & the interior we wanted, not to mention it's got a lowered beam and front coilovers along with the much better brakes and larger driveshafts etc so will make the Turbodiesel project loads easier/quicker and cheaper.

Still undecided but we may use the hydro clutch setup from this car too, would make things simpler short-term but really would prefer cable operated push clutch if possible. Got a day's insurance to burn though for now, so off to give the old girl a last hurrah.

ekjdm14
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Re: Tales from beyond the grave AKA Dan & Emma's Black Xantia, pug 206HDi, Daniel's 206 Verve 1.4i, GTi180 + XUD9TE 206!

Post by ekjdm14 »

Not a huge amount of progress this last few days, waiting on service parts for the XUD as well as still missing the top engine mount & inlet manifold. Have spent some time giving the lump a good clean up and a splash of paint on the block/sump though so at least it'll look halfway decent, when the pump seals & cambelt arrive I'll give it another fire up to confirm whether we're keeping the original turbo for now or going straight to a TD04 unit.

ekjdm14
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Re: Tales from beyond the grave AKA Dan & Emma's Black Xantia, pug 206HDi, Daniel's 206 Verve 1.4i, GTi180 plus XUD9TE 2

Post by ekjdm14 »

Missed taking some photos this evening, engine/box now sat loosely in the car (second dry fit) & looking nice with it's freshly painted block. Still waiting on cambelt and manifold gasket but pump seal kit arrived so will get a pump ready when I have time in between other bits as it's something doable on the bench indoors.

ekjdm14
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Re: Tales from beyond the grave AKA Dan & Emma's Black Xantia, pug 206HDi, Daniel's 206 Verve 1.4i, GTi180 plus XUD9TE 2

Post by ekjdm14 »

The word for this evening is-: OUCH!!!

Nothing too major, but boy have I ever caught the sun today... All across my back, neck & shoulders. :oops: Had virtually no sleep last night, so the obvious thing today was?... To crack on with stripping the parts GTi. (actually, not so daft. Mentally tired but body rested = ideal time to do the grunt work, especially since I've got to know the 206 pretty well so could more or less switch brain off and let autopilot take over.)

Unfortunately having the brain disengaged also meant I never for a minute considered the wise words of Baz Luhrmann, to wear sunscreen. As a direct result, about 10 hours spent working largely topless due to the heat means I'm now doing a passable impersonation of a lobster. Ho-hum, at least the majority of the bits we want are off the car now.
Just the interior which isn't so bad (& the boys want to pull that out but will have to wait till it's cooler as not having them heatstroked) plus the rear beam to drop out which is a matter of 4 bolts, 2 handbrake cables, unplug ABS sensors and undo the brake lines. Then the poor old carcass can go on it's merry way to the big B-road in the sky, I feel better about it now though having had a good look underneath & behind the headlamps at the structural rails, it's pretty rotten and there was some oily mayo in the top hose/radiator too. Not that it was a horrible car, the mechanicals seem to have been well cared for and the suspension/brakes etc are great, it'd just done huge miles. (odo said 175k but it's been broken a while, my estimate is north of 200k).

I'm currently thinking on whether to use the GTi gearbox with the TD swap, my reasoning being that it's not a motorway cruiser or long hauler we're building but a fun toy that should be able to truly shock some higher pay-grade motors on twisty, hilly roads whilst not making a racket about it like the 180 & costing negligible amounts in fuel. 8-) I reckon with 5th giving around 2800rpm at 60mph it should be OK and if it's not, I'll just swap over to the 406 'box or possibly swap the final drive if it fits.
Not long now till the real fun part can begin, putting things back together.

ekjdm14
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Re: Tales from beyond the grave AKA Dan & Emma's Black Xantia, pug 206HDi, Daniel's 206 Verve 1.4i, GTi180 plus XUD9TE 2

Post by ekjdm14 »

More progress. Interior, doors etc off the parts car & pulled the wings off the '03 ready to swap to the wider GTi ones as well as to repurpose the evap line from the carbon canister into a diesel return pipe (the 1.1 used a deadhead fuel rail, not ideal for derv).

Not a huge amount due to the heat and being half cooked from yesterday still, but we're moving along.

ekjdm14
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Re: Tales from beyond the grave AKA Dan & Emma's Black Xantia, pug 206HDi, Daniel's 206 Verve 1.4i, GTi180 plus XUD9TE 2

Post by ekjdm14 »

Parts car went on Tuesday, we barely had the thing a week! Just awaiting a parcel from evilally and we'll have our inlet manifold then (along with a set of spare recon injectors for Black :) ). Going to have to do some tomfoolery with bellhousings and pressure plates to get the clutch setup I want, Still undecided whether to use the 406 HDi 'box or the GTi as it's mainly going to be a B-road toy not a motorway cruiser. Was hoping to use the GTi clutch as it's nearly new but the disc is a little bigger than the TD (no problem, it's only about 8mm) and the flywheel side fouls the TD flywheel (end of idea!). Pressure plate no use either as it's a bigger PCD. Almost wishing I'd kept the flywheel off that engine now but that probably would've caused other issues.

Only other option with what we have, is to use the complete HDi setup including the DMF but that felt a bit wobbly. So will be on the look out for a push type pressure plate to fit the TD flywheel & either a new TD friction plate (on GTi 'box) or find something to fit the HDi's larger input shaft but with damping springs instead of the DMF.

Also need to sort injectors out on the TD engine as they're dribblier than Scott Turner's sidekick.

ekjdm14
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Re: Tales from beyond the grave AKA Dan & Emma's Black Xantia, pug 206HDi, Daniel's 206 Verve 1.4i, GTi180 plus XUD9TE 2

Post by ekjdm14 »

Been a while since I posted an update on the 206 TD project, car is coming together nicely and starting to look like a vehicle again. Engine/gearbox are mounted, ended up buying a GTi180 flywheel as that was the best option and allowed re-use of the new clutch kit from the parts car. There's been a few bits that've fought me hard, gear linkages needed to be extended, 2 engine mounts fabricated from scratch & the conversion from cable to hydraulic clutch was painful since I had to remove/refit the pedal box, a job no-doubt supposed to be completed with the dash out but I wasn't for doing that!

Cooling and induction system was tight to pipe up, ended up with the GTi header tank in the plenum part of the scuttle panel under the bonnet vent & the Xantia TD rad and intercooler juuuust about squeezed between the front chassis legs with a bit of "massaging" the metalwork, 206 slam panel/rad mount had to be chopped up & just the (heavily relieved) slam panel part of that remains, radiator and IC are slightly tilted forward at the top & will have to cut the grille/bumper to clear them and the fan once the "face" goes back on.

The multiplexing is causing a few headaches (mainly due to wire numbers having faded/rubbed out, helped ably by Mr Haynes' manual living up to it's nickname the BoL!) but we'll get there in the end, think it's narrowed down to a VAN line issue.

Apart from the electrics/electronics side of things there's just the suspension/brakes to swap, a coolant leak at the back of the engine (shades of Black's engine replacement, although don't think it's the water pump this time!) to sort, and a missing intercooler pipe to find and then the bodywork can go back on & she'll be ready for tentative first testing.