Andyyy's 1.9 DT 205 Cherry Red VNT

[andyyy]

Thanks I was going to reduce down for the connectors but if it won't fit the clips either I'll just get some 8mm ID tube

[andyyy]

Made a fair bit of progress with this lately and is very close to a first start now

Made up some oil lines for the turbo




Put the battery in the boot and connected it up



Made up a mount for the radiator 


Then sprayed it black



Made another one for the intercooler but cant find any photos of it

Random photo whilst I was mocking up the intercooler, had to cut a little bit out from behind the bumper



I’ve cranked the engine over and all sound sweet, as it should after all the work that’s been put into it.

I’m waiting for a few things to come in the post, and I need to get a fuel line for the 3rd injector (might just bend one up to get it going) 
 
Also got all the wiring into the boot so as I can run the front washers from the tank in the boot to save so more room in the engine bay and keep it looking tidy 

[andyyy]

Been really busy with work and other things lately so unfortunately haven't had much time for this

But on Sunday I got the day to my self went down to the garage determined to get this running. After a few hours by lunch time I was ready to turn the key and give it a go.

After a 30 seconds of turning over she spluttered into life so I ran it for about a minute shut it off and filled the cooling system and bled it.

Started it up again let the last of the air out the coolant and let it run for about 10 minutes before I ran out of time again.

It did run a bit rough (engine moving around a fair bit) but I think that's to do with the fuel pump being left for nearly a year dry, not cracking any of the injector lines and the year and a half old veg in the tank!

Appologys for the photos or videos, there will be soon.

[Piggy]

Good news!

Hope that pumps ok after that long!!

Get some fresh diesel in here and lets see a video!

[andyyy]

Good news!

Hope that pumps ok after that long!!

Get some fresh diesel in here and lets see a video!

Thanks, yeah I hope so too ! With any luck I'll be getting it running again over the weekend so I'll try to grab a video , and attempt to upload it. 

Managed to get a hour or so today so popped over to the car and found that the lower engine mount was only on by a few threads on all the bolts ! 
So that could account for it seeming rough and bouncing around a bit. So I'll be thighning that up and having a good check of everything else !

[andyyy]

So managed to get some time this morning as I busy all weekend I got some time off today as I'm going to be working till 5am. So I went over to the garage tightened up the lower mount and got her going again. 



First video is when it's just started and was still rough

http://vid1172.photobucket.com/albums/r5...wb7iyh.mp4

Once it warmed up a little I tried to figure out why it was rough fiddle around tried a load of different things, gave up in the end and gave it a good rev and it chucked out a load of white smoke and ran perfectly, must of just cleared itself out. 
 
http://vid1172.photobucket.com/albums/r5...mmi4k6.mp4

Still need to get some new diesel in her rather than ancient veg and the gearbox is definitely shot but iv got one off the HDI that I salvaged before it died.

[Paul_13]

Before it died?! Christ your memory failed you

Seriously, you around tomorrow night I'll come over and have a look

[andyyy]

Before it died?! Christ your memory failed you

Seriously,  you around tomorrow night I'll come over and have a look

Alright before I killed it lol 

Tomorrow I plan on sleeping most the day as I'm working till 5am now then I'll be doing emails and boring things for work might be around on Wednesday tho I'll see what the day brings and let you know

[andyyy]

Was over at the garage for a little bit today started the car up to make sure it gets a run every few days now that it actually runs, then decided to paint my hubs I got at the weekend.

 I got them because the wheel bearing are shot on the car and was cheaper and easier than getting them pressed in and out. Since the gearbox is shot I'll be putting them on when I get a chance to change it. 

[Ruan]

That noise is a valve stuck open minutely in the first video - XUDs ALWAYS do this first start after having the head drained, then will clear themselves - lucky it didn't happen on more than one cylinder, can be an utter TWAT to get started once it's happened!

In future, IME simply pouring a litre of oil in the top end to top up the initial oil fill before starting usually solves the problem.

[andyyy]

That noise is a valve stuck open minutely in the first video - XUDs ALWAYS do this first start after having the head drained, then will clear themselves - lucky it didn't happen on more than one cylinder, can be an utter TWAT to get started once it's happened!

In future, IME simply pouring a litre of oil in the top end to top up the initial oil fill before starting usually solves the problem.

Ahh okay thanks was wondering what it actually was, will do that I'm the future. Weird that iv never had it before doing head gaskets and such then. Thanks for the advice !

[andyyy]

managed to grab some time today and paint the gearbox ready to go in as soon as I get a chance ,ignore the "borrowed" air port trolly  

   

   
Whilst I had the brush out I gave the callipers a going  over
   

[bashbarnard]

I love how much effort people go through with these and paint. Im lazy. Gave mine a clean and went. That'll do. Just concentrated on a tidy install. Lol

[andyyy]

He he , the paint stops you getting as filthy when inevitably some major repairs need doing at the road side, normally on the way to going to see relatives that haven't seen for a long time or a nice dinner! 

Did something today other than painting took the driveshaft out and put 306 end on as I suspect it may be the diff that's gone in the current box so iv got no diff to swap over. 

Few photos of how it went 

   
           

The difference between a 205 end (left) and a 306 end (right) 
   

[Paul_13]

Bodge!

[andyyy]

It is a bit just didn't want to waste ages of time getting hold of a 205 diff when I had all the rest of the bits left over from the poor HDI - atleast it went to good use!

Small update of random happenings over the week 

Gov mod
   
   
   

Swapped gearbox selector arm - what a b**ch broke a punch, hit my hand twice and broke the speedo drive somehow 

   
   
   
   

Also this came out of the old gearbox - definitely shot 
   

[Mattcheese31]

Yoiks!!!! Who's been boning the gearbox and leaving their manjuice?

[andyyy]

Yoiks!!!! Who's been boning the gearbox and leaving their manjuice?

He He 

[andyyy]

So stuck the new gearbox on last night 
   

Then completely failed at getting any more photos after I put the inlet hubs etc all back on. 

Wont be long long before I find out of it drives now, but I'm off to Spain for a week so won't know until after that !

[andyyy]

Put the engine back together then worked out the intercooler piping again as wasnt very happy with it last time, need to but 2 more 90s as its 2 reducing 90s bodged together atm and eventually will all go blue with black metal, except behind the bumper which will all be black. Painted the cooler black aswell as dont want it too obvious. 
   

[Piggy]

That looks bloody nice

[andyyy]

Thanks! Should look better when I get the blue silicone but for now the black will do. 

Today I finished the radiator/intercooler mounting bracket thing me and my mate made. I wanted to keep it removable cause it made taking the engine in and out soo much easier so drilled some holes made another little bracket and bolted it to. 
Excuse the hidious welding on the bracket, it wasn't me I swear ! 
           

Then I stuck the bumper on to check clearances and all is good, need to move the licence plate or it will block the intercooler though 

       

[Paul_13]

Does the boost pipe in the middle clear the grille?

[andyyy]

It will when the 90 iv ordered turns up, currently I don't think the left one will

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Also I need to get hold of the plastic grill that attaches to the valance below the bumper. If anyone has one there willing to part with let me know !

[Magenta Sunset]

have you secured the battery down?

[andyyy]

No not yet, been concentrating on other things, I plan to just use a regular battery clamp with a stud coming up through the floor.

I did wire in a proper earth for it today though (another part I nicked off the poor hdi) as I got sick of the jump leads falling off all the time.

[zx_volcane]

This is shaping up to be a fair tidy build, nice work

[andyyy]

Thanks its good to hear people are liking my work! 

Can't seem to get the rev counter working, bought a new sensor yesterday as I thought the old one might of had it. When I plugged it in I notice the red and white swap, should I swap them back or is this normal ? It's like this on both sensor's. 
   

[td_dan]

I had the same issue on mine and bought a new sensor but didnt work.

If you look at the clocks from the driving seat position there is 2 earth plugs beside them make sure they are plugged in as mine werent causing the gauge not to work if not i can send you the bramd new sensor i used as its tested and working

[Paul_13]

Check you have a 12v feed to the Rev counter plug

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Pin 3 from memory