205 Sport Van, Supercharged GTI6

[allye]

Hello all,
I want to post up wanted threads but cant due to my post count so thought I’d share my 205 van project and get more involved on here. I tend to stick to 205GTIDrivers. I currently drive a 309 GTI Goodwood with a 406 V6, you may have seen it advertised for sale but likely will not sell it as I like it too much!






The first car I built but a 205 Rallye with a 306GTI6 engine, stuffed that into field and bent the chassis, reshelled it into a XS then sold that a while later. Fully went to town on the Rallye actually, rebuilt everything, was a shame but learnt my lesson on that one!







I had a 205 Van at my first car, also stuffed that one down a country lane! Here the new one, 165k on the clock, ex fire service van and very solid all round.

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I had wanted to stick a HDI engine in it, more refined and easier to tune, but as a 1.9DT drops straights in no problem I decided to keep it simple. The idea of the van is generally standard suspension all rebuilt, fully sound proofed and a mildly tuned 1.9DT engine. Decent MPG, fun to drive but comfortable. I've got a full GTI interior for it too.

Engine has HDI rods now, Darren said he will mod the pump for me, 9mm etc etc. HDI gear box and a front mount. As you can see I'm rebuilding most of the engine in the persuit of reliability! The donor car was a 1993 306, bosch engine! Actually older than the van.

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Then when putting the oil pump back on yesterday this happened, an repair has been planned and I'll give it a go next week.

[7057sam]

309 and 205 are pure porn mate

[Uberderv]

Very nice Shame you went XUD in the end.

[allye]

I'd still the Rallye now if I hadn't bent it!

Uberderv, HDI can be a future plan when you write up a conversion guide for me

[Stef205]

Seen as you won't let me eaton the 309 anymore can I at least eaton the van?

[Niall]

That 309 is awesome. I remember seeing that at pugfest and loving it!

[procta]

that 309 looks pure mustard! I bet its shocked a few people with it having a V6 dropped in!

[allye]

Thanks chaps, the old green peugeot has embarrassed quite a few. 330i's, S2000's and many more!

[Poodle]

Nice collection, i look forward to seeing this one come together.

[procta]

Thanks chaps, the old green peugeot has embarrassed quite a few. 330i's, S2000's and many more!

its the look on their faces isn't it! Retro sleepers rule!

[allye]

I've not taken notice of their faces, but certain german cars do not take kindly to it at all, I've had a few cases of serious tail gating after a over take!

[procta]

I've not taken notice of their faces, but certain german cars do not take kindly to it at all, I've had a few cases of serious tail gating after a over take!

I have had that too, yeah german cars don't like it at all, I have had a chase or too as well, but still had the run.
few attacks off Nissan micras, various fords, odd couple of Vauxhalls, are normally the thing with me, Mainly the micra lot, but they always get shown up badly!
you got a build thread on the 309?  

[allye]

Jeram originally built the car, a long term 205GTIDrivers member here;

http://projects.205gtidrivers.com/jeram

He did a very good job on the hole, although I have done a lot of improvements with it, when it came to me it had cut springs, radiator fan was not up to it and some very questionable fuel lines! Here my sort of thread;

http://forum.205gtidrivers.com/index.php...pic=146317

[THE_Liam]

All the cars in this thread are amazing, good work! Being a '93 engine that should be a D8A I think?

[allye]

Well it's certainly a Bosch, whats a D8A?

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Quick google, early none egr/cat engines. good one then

[Ruan]

Yeah, the earlier ones...

Definitely is, there's a little silver and black plate riveted to the front of the block. The DHYs don't have that plate, only D8A/D8B

Only disadvantage, from memory is that the D8As don't have the piston coatings that the later DHYs did, nor do they have the steel inserts between the valve seats which sometimes cracked on the earlier engines.

[allye]

Progress has been made, I repaired the block by drilling through a stud into the block and inserted a roll pin, shotgun shell mold, taped to the block, thoroughly degreased and fill with jb weld, job done.





Oil pump went back on and finally got the sump on with a good bead of sealant.

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Finally move my attention to the head get that together, de coked the entire head and valves, gave them a quick lap for peace of mind.



New stem seals, cam shaft oil seal and cover gasket

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Checked the gaps on the camshaft and all was well and with tolerances, must have had some work at so e point, caps torqued to 20nm.



Put a very fine film of rtv stuff on to give it half a chance of not leaking like every other XU diesel.




All done!




I need to get my pump modified, 9mm head etc. Can anyone suggest somewhere?

[Poodle]

Darrenjlobb on here is a bit of a boss with the pumps.

Be interested to see if that "fix" holds lol, good to see she's still progressing.

[allye]

I was in contact with him then he stopped replying!? Anyone else do them?

[zx_volcane]

Not keen on using rtv on the rocker cover / gasket - no need if its a clean surface and you've a decent quality gasket

Most end up leaking becasue the cover has been over torqued - really only need a tiny nip on those three bolts, hardly anything

[Uberderv]

J B weld is awesome stuff As Mr Zx volcane says RTV on there might not work, didn't for me anyroad.

[allye]

Camshaft cover is 10nm, we'll see how i get on, its a very fine film.

[allye]

Anyone interested my Goodwood progress is here.

http://forum.205gtidrivers.com/index.php...=146317&hl=

[Uberderv]

Nice progress, think my next car will be a 309 not being nosey but do you travel in winter for shits and giggles or is it part of your job?

[allye]

I'm a professional beach lifeguard. Yes that is a job! In the UK I work for he RNLI on various beaches from April through to September. My winter seasons vary depending on where I go, Australia or NZ. It's tough but someone has to do it.

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Oh and the small amount of time I spend at home I work part time at a friend garage which allows me to dick about with old Peugeots!

[Stef205]

your a bloody sandal princess!

[allye]

Shut it you slaggggg

[Dum-Dum]

Build looks good but it needs a bigger turbo if your getting a bigger pump.

Dieselmeken in Sweden will do you a pump build, I believe someone here has one of their pumps. https://www.facebook.com/dieselmeken?fref=ts

[Uberderv]

Build looks good but it needs a bigger turbo if your getting a bigger pump.

Dieselmeken in Sweden will do you a pump build, I believe someone here has one of their pumps. https://www.facebook.com/dieselmeken?fref=ts

Mr ZX volcane  has one I think.

[allye]

Only going 9mm, I've been umming and arring about the blower for a while a td04 came up on Facebook with manifold ready modified too but the aim of the build is reliability not headline power figures, I have the good wood for outright speed.