gt2259s Dturbo

[n0v0s]

Now that my exams are done, i thought i'd stick up a quick intro to my Dturbo before all the major mods come in the next few weeks. I never keep cars for long. Get bored too quick. I only bought it as a temporary stopgap car to tide me over a few weeks at Uni at the start of the academic year but.. i still have it :? . As much as i hate the bastard, i also love it. Can't explain it tbh, i guess you could say i live for the 306 now

(none of my car fwweeends understand it tbh! Seeing as i used to drive these...

330d


S4 B5






Anyway, some random pictures from the past 8 months to follow. Nothing special just yet, it was mainly a year of bodging; every time the car broke down - i just bodged it with what ever i had lying around and replaced with standard turbos...




Replaced soon after with..


And some of these after a near death experience




Then the winter came, and with it, the joys of trying to start an xud with 2 glow plugs on gloopy used veg


Thought this was fitting (my friend has a really odd long thumb hock: )




Various breakdowns, have more somewhere..




6.30am M6 casual breakdown, nice sunrise though. Pump pulley come loose.


Fixed with this


Followed by this KABOOOOOOM and a Geordie 'noooooooo'


Then after a bitter cold winter with no heating, i decided to sort my fudged matrix... for the summer :?


So in summary, i've been through 3 standard turbos, several boost and coolant pipes and 2 pulleys. Not baaad considering its currently clocked up 9k miles of 35psi+ abuse on its 95k miles DHY block with rods still intact Its a laaaate '99 ph2.5 in really good nick with fsh.


Plans for the next week or two are:

Drop in my spare Xantia engine with some gasket matching porting
Bigger turbo (i shall keep this secret for now, but its not a td04/t25 old tech shit.
10mm pump head + other mods
Hdi rods
Skimmed pistons hopefully
DE-ORANGE my engine bay with new headgasket and possibly uprated head bolts
New clutch and Hdi box
Coilovers
And some other stuff


A recent pic with its masked crystals.



The aim is to get it to 200bhp and keep some reliability. It's my daily and i'll be covering about 300miles a week next academic yr.. Its not fun breaking down/fixing shit in a suit! Anyway, thanks for reading and hopefully the next update will actually have something interesting for you to see and read instead

Niv.

[samass]

Nice! You can tell its exam season when this is posted at 4 am

[Matt]

Hahahaha and your still up Sam!

Also loving the gear knob haha!

[mark_airey]

Some awesome bodging going on there

like the pump pulley repair myself..............

[Jtrigga]

Brillant pulley repair I can see why you come back to the dturbo they are so easy to bodge back together

[n0v0s]

Decided to reward the recent display of reliability with a thorough, long overdue clean:













Light was fading and they are only from my shitty old nokia 5800 so not the best of pics..nonetheless they show off the powaaaah of Autoglym and some San Miguel!

[Dave]

Wow some awesome bodges' going on here Niv!!! Love the pulley repair and sock gearstick!! I used a set of undies before haha

I wanna see some awesome photos of your block and pumps builds mate! Let us know what you decide to do with the pump, good choice with the 10mm

You being hardcore and doing it all on your drive?, where are you based?

[n0v0s]

Haha, i wish it was a sock Dave! lmao - Underwear?! Hardcore. Naah this was the cleanest oily/diesel rag i had to hand - but no amount of Little tree pine fresh can quite beat the smell of Eau Du Diesel filling the cabin!

I'll be stripping the xud down complete to check all clearances/condition and rebuilding up as necessary with the hdi rods. Shall snap away with a proper camera so no worries there hah (i go a little too snap happy sometimes!).

And yes, all on the drive. Maybe the garage if i can make it habitable again!. But after chest pressing a 100kg bmw gearbox onto the car from the floor, i think its safe to say things will be relatively less hardcore/easier (i hope!) and do-able. During term time i live in Central Manchester, but atm during Uni hols i'm back home in South Birmingham where all car stuff gets fixed Where are you from Dave?

[ginge191]

Some great work has gone into this mate!

[n0v0s]

I'm bored. So, a small update. Only got as far as removing both heads due to family coming round and i was stripping down a 1.6 16v renault engine earlier to practice grinding the piston crowns..






Factory honing marks on xud..




And some other random 5800 shots;

mmmh, maybe.. if the piping fouls the master with the tmic


Day after i cleaned the bugger too :roll:



And finally, some beadage!








Bloody hockey sticks!

[Louis123]

Looks nice mate paints got a lovely finish

[n0v0s]

Right, about time i updated this..

I've been building up a spare low milleage DHX xantia lump with HDi rods/shells and low milleage HDi oil pump. While the block was apart, i took time to hot steam clean all the gunk out with detergent. The block is in excellent condition; the crank surface was immaculate with no scoring on the bearing surfaces or bores and the factory honing marks still present.

I've spent quite a lot of money/time on it, including;

cam and crank + various other seals,
New cambelt
New sump and manifold gasket
head skimmed + mls headgasket + new headbolts
rocker gasket,
New valeo clutch + cable
New stem seals,
Cleaned valves (also re-lapped) and the head of all the gunk
Additional tarting up

Currently working on building up a spare hyrbid Bosch pump with 10mm head. The internals of which have mostly come from a 500mile (no typo) old bosch that i've had lying around since coming off the car yonks ago!

The turbo is a monster garrett ;D which is in great condition. Just need to finish making the adapter plate up.

Anyway.. pics! ..

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Ignore the manifold gasket, i changed that for the correct type

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f*ck all wear









Just for lols, a corsa turbo on top of mine

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There was SOO much shit inside the inlet part of the head, it was unreal!



Nice job Peugeot! NAAAAGGHHT!!

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MMMmmmh noiiice!

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There it is, just chillin' .. unaware it's about to have it's guts ripped out





Pump carcassed;

---

Old pump; internally it is fine, very good infact. The case however..




Still works great with the rear bolt in, was sufficient!

Think thats enough pics for now. Have a lot more that i'll get up some time soon.

Niv

[zx_volcane]

nice progress, theres nothing like seeing an engine in bits

[Dan!]

Great work fella, should be good fun when its all built up

[Jenkosowls]

Epic!

[n0v0s]

Cheers lads! Can't waiit to get it finished! Makes a change to be spending big monies on it.. as i want it done right, no bodging or cutting corners.

If she goes boom, then it's going to get stored away while i put my 330d back on the road ( ) .. so she better play nice!!!!

[n0v0s]

It's been a while since i've updated this! The cars been off the road until now as i had issues with my fuel pump and very little spare time to try fix things due to having to start Uni and hospital placements. This meant i had to buy something reliable..



Excuse the shit pic. It's an 204bhp (m57n engine) 330d sport with a 6spd manual in individual spec Le Mans Blue. Amazing car. Even though its standard, it easily walks a decatted 231bhp rx8 (gutless shite!) whilst returning an average of 49mpg over the last 3k hard miles (75% Mway). It does everything really well. A well rounded car. But it's no 306

... Anyway, i've managed to sort things with the pump, and she fired up for the first time in 6months today on its newly rebuilt engine and rods, no drama at all and sounds sweet such an awesome feeling of joy upon hearing that all so familiar idi clatter thats been missing from my life (the bmw doesn't sound 'diesely' at all!!) and after all the hours of swearing and effort building it up, it now feels worth it.. Even if its quite likely to blow up..

I've not really mentioned anything of the turbo until now. It's a garrett gt2259s.

2259s vs t2




It was quite a bastard to fit and it's compressor housing is MASSIVE and the exhaust flange is elongated meaning it majorly fouls the bulkhead and servo and proved to be a major headache to fit. I don't recommend it at all. Effectively, the engine is now solidly mounted due to the turbo still fouling and so the vibration and noise into the cabin is just ridiculous in its current setup. But it should be more than capable of producing rod spitting power!! The 10mm is fueling epicly compared to the 9mm too.

Will take it for a quick drive tomorrow. Can't wait!

[Pompey306mark]

Very good work. Hope it all goes well.

Might be wrong, but isn't the dhx engines suppose to have better/different internals to the standard d8a and dhy engines?

[n0v0s]

Cheers

I think out of all the rod spitters, the dhx have thrown the least. Not sure if they have different internals tbh. Certainly looks to be the most reliable standard block. The block probably does has some slight differences in construction due to technical revisions in newer dhys

[ozonehostile]

Im liking how detailed your project diary is, I wish I was organised like this, but no, I just do a ton of stuff then think "oh shit I forgot to take pictures......again" keep it up though, I will defiantly be keeping an eye on this

[Pugmarshall]

Looks good, needs more engine pics

[n0v0s]

Cheers lads

The spool is fkin AWESOME, as is the coal

[Anton]

Hows this going?

[n0v0s]

Hey,

It's currently sorn'd. Not got any time for it. I really shouldn't but I'm getting the urge to sell the 330d and use the pug as a dd. in the next few months I'm going to see if I can sort the turbo clearance issue out to see if its feasible plan. I feel like I've wasted my rac membership this year :p

roll on summer hols!

[Ruan]

Get yer grinder out!!!!!!

[n0v0s]

Haha, that depends on how bored i get!

I'm probably just going to lash up a temp top engine mount to pull the engine forward, if it means I don't have to disturb anything else.

[Jarrus]

Temporary top engine mount FTW,
I was in exactly the boat as you when I fitted my GT2560R on the back of my 1.9, fouled the bulkhead and made a top mount to move it forward....
I have a picture on my laptop but i need to find a new photo hosting site
Apparently the one picture i put up of a scantly clad lady was porn...so photobucket say....

[n0v0s]

Temporary top engine mount FTW,
I was in exactly the boat as you when I fitted my GT2560R on the back of my 1.9, fouled the bulkhead and made a top mount to move it forward....
I have a picture on my laptop but i need to find a new photo hosting site
Apparently the one picture i put up of a scantly clad lady was porn...so photobucket say....

Hey up Jarrus, there's imageshack and Flickr. Ah yes I do remember seeing your diy top mount! Any top tips mate? I've got some steel plate handy but not really looked into this properly..

How much forward did you manage to bring the engine? Did you have to modify the lower fork/mount and or gearbox mount at all?

I really could do with at least 0.5inch as the steering knuckle is probably 1mm away from the comp housing on idle! Cheers

[padge]

any update?