205 HDi :)

[Uberderv]

The plan for the cooling system was to use the original 1.8td rad as it has a large cooling capacity. The Alternator sticks out far too much to use the original cowling/fans-

I made a frame that used the original radiator support but brought the radiator forward-

This was ok but when trying to refit the bumper the radiator was in the way. Solution was to cut the front of the car off and build a 1" angle iron frame to support the radiator, this put strength back into area and tilted radiator to allow the bumper to fit.

Now I was happy the rad was in the correct position the rest of the cooling system was connected up, this was also a PITA and if I ever do it again I will use a different coolant distribution housing, possibly off an 806. With the system topped up I finished off the wiring so I could get the thing running. Rigged up a temp fuel source and charged the battery.......

Turning a freshly cleaned HDI engine over with no exhaust in a poky little garage wasn't the nicest experience ever but had to be done. After a couple of runs to get oil round things and let it settle down I let it run up to temp and found the stat was seized. Replaced that and ran it again, it was smooth as owt

Quietly chuffed that drunken mechanics works (again) I started to get the rest of the engine related stuff ready, the gear linkage was right in the way of the rear boost pipe. So made a new lower pipe like the C5 pipe and also sorted the down pipe out to connect to the original exhaust.



As I had decided to chargecool the engine I got that fitted so the boost pipes could be completed-