Stage 2 China HDI daily

[deggerz]

I know me and a few folk on here don't see eye to eye, but I get along with the majority of people and due to boredom at work I thought I'd keep track and post a thread here

So as a few of you might know I moved away from 306s a few years ago and have been driving a Megane R26 for a little over a year, until recently when a rod made an escape for it

So whilst the Megane is (slowly) being forged I needed a cheap daily and ofc we all know the go to car for that job

So here is it a bone stock 306 HDI


And one with the broken meg


I bought he car knowing it needed p bushes on both sides, so first thing was to replace both wishbones along with ball joints and new pinch bolts

After driving it for a few days I started to get a little suspicion the turbo wasn't quite right, it drove fine etc but just a little niggle in the back of my mind,

Fast forward about 7 weeks, driving to work the gearbox decided enough was enough luckily I managed to limp it home with some epicly good " that's f*cked mate" looks from some members of the public [emoji23]

So with having to do a fair amount of work and the worry of the turbo in the back of my mind , along with the crank pulley rattling it's tits off, I decided to pull the motor







So I started work getting the gearbox off, and getting the paddle clutch in which had kindly been donated to me which I sent off to get relined as it wasn't really that old, not 1 drop of oil had come out the gearbox on removal of the driveshafts and the same story with it on the bench. That why it'll be knackered then [emoji23][emoji23]



New release bearing and driveshaft seals were fitted to the box prior to refitting





So with that done I moved onto the turbo (The whole reason I pulled the engine),

Fortunately this ended up being the correct choice as upon inspection there was an extremely large amount of play and it wouldn't of been long before it'd have let go

( video won't upload)

Luckily I had already sourced a spare K03 ready to fit which I did along with removing the egr system from the manifold and fitting a 3mm mild steel blank plate



So with that sorted I moved onto fixing the crank pulley,
Upon removing the bolt it immediately became apparent there was something else wrong in this area so with a little persuasion I was greeted with a massively distorted woodruff key and a knackered sprocket



So I managed the carefully grind the front of the woodruff out allowing me to remove the sprocket, I then found that the actual keyway on the crank was also massively distorted meaning theoretically I'd probably need a new crank, but that's not happening , as the woodruff isn't a load bearing part I can only assume the bolt wasn't torqued correctly previously causing slack and the damage



As you can see in the picture I also installed a new crank seal as that was leaking pretty badly,

What I actually decided to do was pack the woodruff in with a large amount of chemical metal to try and stop any movement







I then installed a new crank pulley which I will torque up to spec before running the engine to try and save the woodruff from the same fate as the other one

(Before people moan about this bodge, I know there's probably better ways of doing it but this is what I had to hand! Fingers crossed it works of not I'll work on else)

The belts were done about 5k ago but as I was there i put a new belt on as a matter of course, I also installed an R70 pump which I didn't take any photos of ,





I also removed the AC pump and installed a 6pk1173 belt


I then mounted the 406 110 elbow which had been decreased and tapped to allow a boost guage, along with the the egr blanking plate


Then I installed a Turbosmart manual boost controller and bolted it to the inlet manifold using one of the taps where the EGR system would have been bolted to

Then onto the lower engine mount which I replaced for the "Red" diesel power flex mount

No photos of any of that unfortunately


I then went onto prepping the car for the engine going back in, I removed all the AC pipes back to the block on the bulkhead, and then removed the EGR and air doser solenoids rerouting all the vacuum line as to delete it entirely from the car

Unfortunately no photos of that either

We then just before it got too dark managed to drop the engine back onto its mounts





And that's how it sits at the moment

This was done in the last 2 Saturdays as I'm limited on time and ofc light. Due to work commitments

This project isn't for all out power I just want a reliable daily with a bit more oomph than stock
For anyone interested the car and engine are on just shy of 200k!!

Oh I managed to pick up the intercooler too!


Thanks for reading , I'll be along with more updates soon





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I forgot to mention the car was also dynoed by the previous owner where it pulled something like 78hp, so once it's done I'll be back to the same dyno so we can see the difference in power


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