205 HDi :)

[Uberderv]

With plenty of spares I completed building the engine, taking rough measurements it turns out the rear engine mount/intermediate bearing housing are in the same place so that should save having to cut/weld the rear fork.
Started building up the intake and boost pipes -



Initially I wanted to make the intake an improved version of the original intake so this was version 1 -



Then decided that I was going to chargecool the engine and it was going to get in the way so settled on this-



The MAF sensor fits directly in the 3" pipe then it goes off to the filter.

For the boost pipes, I wanted to take them up the tradesmans (oooeerr missus) side of the engine to keep pipe runs as short as poss. I made a little jig so the cooler and engine were in roughly the right place then made the pipes-


Then made a stainless version or the rear pipe -


With the pipes pretty much done it was time to tackle the wiring. The common rail fuel system is taken care of by a Bosch EDC15C2 ECU and all its various sensors. Below is a pic of the engine loom and ECU -



I stripped the loom back to bare wires and removed anything related to the following-
EGR
Aircon
3rd piston deactivator
Additional heating system
Fuel cut off switch

I also shortened the remaining loom by approx 15" as there was too much spare wire for were I had decided to fit the ECU. The ECU has to have the immo codes removed for the engine to work outside of the original vehicle, I think it has some sort of hand shake system with the alarm/BSI and until its happy it will prevent the car from starting.
Luckily there was an ECU on Ebay with the codes removed so I purchaced that and got another one with the same HW/SW as a spare for when I start mapping it.



Once the loom etc.. was finished it was clear that the rest of the work had to be done on the car, I moved the battery to the boot to create space-



Managed to scrape some pennies together and buy another WVO daily driver, 2.5td Mercedes-



And the 205 was finally rolled into the Batcave at 180k of almost trouble free motoring.