205 HDi :)

[Uberderv]

Once the Chargecooler was fitted the bonnet wouldnt shut all the way so I trimmed a bit out of the under frame. My plan was to fit the Chargecooler pre-rad on top of the radiator. I measured it up and researched different coolers, it turned out that a Range rover P38 oil cooler was the perfect size to fit in the space. A mate in work had a knackered one which he gave me to test-




Unfortunately, fitting the pre rad there meant that the original bonnet latch was in the way and had to be replaced with pins (There goes the OEM look )
With everything in its rough position I got the bumpers on using a few home made securing methods. Turns out the bottom of the lowered rad framework was peeping out of the bumper, X1 laguna splitter later and it was hidden.



At this point we moved house again so work on the car stopped for quite a while. The above pic is the car moving into its new home after sitting outside under a cover for months. Finally got to work on the car and decided that the chargecooler pre rad was going to be too small (no other possible mounting position) . Options were to get a custom thicker pre rad made or intercool the engine. I went for the intercooling option.

The common intercooler which is used on a 205 is the cosworth intercooler, I picked one up but thought with all the hassle its going to cause I might as well get the biggest possible cooler I could.

Cosworth 2wd-



You can see that there is still a fair bit of space left for more cooling. Bit of research later and I had an intercooler off an E39 BMW which is the perfect fit-



Started to make the new boost pipes-



I have had to remove the original fuel filter housing and fit an inline filter as it was in the way. Got to order a couple of silicone hoses to finish the pipe work off. After that its new brakes, New tyres and a drivers seat belt then MOT