305 Dervmafia Winbus

[Sambarker]

Ok so this is due a bit of an update

I suppose last post I was starting to put it all back together bodywork wise and sort out the final hdi running issues.



Welding panels into place



Diagnostics



Fiat punto 1.4 gt aluminium race rad



Starting to take shape



Almost finished



Bodywork done.



I had quite a lot of issues with fuelling, and getting fuel from the tank to the engine through a lift pump and keeping it at a suitable pressure etc. it turns out the walbro in line pump I had did not like pulling fuel from the tank, even when positioned close to the tank.

So to rectify, I had to use a 206 hdi lift pump from a spare car and this solved all the issues



And with that I was back on boost



So headed down to Cornwall to do some tuning



And got it on the rollers for a base figure on the stock map

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First run on the dyno was about 89bhp.

By then end of the day we had squeezed out a reasonable 138bhp.





Good derv Mafia turnout



So moving on, the car got remapped a couple more times to fine tune, and then the annual euro trip took the car to Croatia and Italy on an epic adventure











Completed the journey with only a couple of very minor issues!

Once the trip was out of the way, progress could then be done in relation to further tuning the hdi motor.

So another trip to Cornwall resulted!



And a gearbox change while I was there

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After numerous runs on the dyno, tweaks to the map, turbo etc etc the highest figure achieved on the dyno was

176bhp and 288ftlb

Not a bad result considering this was still on stock R65 pump, rail sensor and injectors.

This was with turbo set to 1.8 bar



However as a result, the return journey had a slight issue or two





Split boost pipe and broken wishbone bush.

This we're both addressed shortly after with a 4 ply hose and a wishbone bush sourced from the spare car.



Spare 305 going to scrap, been useful for a lot of bits but not a lot left of any use.

A few weeks ago had issues with power loss and smoke from engine bay, which turned out to be a snapped stud on the exhaust manifold to turbo adaptor



An absolute PITA to change, but finally got it all back together yesterday and got round to fitting the 2.2 hdi r70 pump I've had for a while.

Once back together had issues with back pressure but this was quickly diagnosed as sticky turbo veins which was fixed by shoving the air line onto the actuator.

So an up to date spec list of the car is as follows:

1988 305 GLD estate (originally 1905cc nad)

110 2.0 8v hdi conversion from 2002 xsara
Forged connecting rods
Fully recommend head with victor reinz head gasket and xud style ARP head studs and custom spacers.
R70 2.2 hdi fuel pump
Volvo GTB2056VLK @ 1.8 bar
GTi6 flywheel
Xud style CG Motorsport 4 paddle solid clutch
Hdi gearbox from a 306
3 inch turbo back straight through exhaust
Charge cooler with custom inlet manifold and front mount rad
MBC

405 mi16 front brake setup
Citroen c15 rear axle with custom spring shims
Gti6 steels, 195/50/15 front 175/55/15 rear

Scan gauge II
Stack egt gauge
Tim boost gauge
Tim oil pressure gauge used for EMP