Someone will likely come along and whine about this post but the HDi is not as prescriptive as say the VW 2,0TDi movement (they tend to have X turbo, with Y intercooler and Z piping)
Find something that Fits, and use that as there is LOADS of room in and around the front bumper, but you will likely need slim line fans. SPAL make nice cooling fans.
Hoses, silicon and alloy i purchased from http://www.autosiliconehoses.com/ Cheap and nice quality.
as to configurations for the intercooler, Twinpass with both hoses coming through what would be your drivers side is slightly easier, as there is more of a gap on the gearbox side of the vehicle, or a single pass and run a pipe back across the top is also common, there doesnt seem to be a particular type that people use, as big as you want (there are some as large as the radiator itself on here for some of the builds)
You are more flexible with the positioning of the cold air inlet to the turbo as the M/C is on the other side of the car. if you have a look at my project thread you will see the cold air feed from the air filter comes across the front of the engine and then down under my master cylinder (drivers side, your passanger) into the turbo, and the high pressure from the turbo came out of the top of the turbo, along the back of the engine and across the gearbox.
Ideally you will need the inlet elbow from a 110HDi to deal with the Cold side into the inlet, this is the simplest to way to get the intercooler piping in, the inlet manifold itself is the same but the elbow bolts on
this picture has one with the EGR port cut off and welded (you should remove the EGR)- this one is from this forum Speak with Poodle or Jonny on here as they sell blanked ones for reasonable prices
![[Image: Pug406l-bendDE-EGR02.jpg]](http://i245.photobucket.com/albums/gg47/Dum-Dum1986/200bhp%20project/Pug406l-bendDE-EGR02.jpg)
As for a boost controller, http://www.ebay.co.uk/itm/like/220537042109 is a good shout, i have one of these and it does the trick nicely..
Gauges, obviously TIM turbo and Stack etc are good, pricey but good quality, but its really uip to preference and how much you want to spend.
With regards to turbos, again it depends on how much you want out of it, 150 is comfortable with good intercooling on a standard turbo (if pushing it a little) but it runs out of puff around 3500rpm, GT20 series is a good upgrade for, GT2056s seems to be a common choice, IHI RHF4 and RHF5 seem to be popping up as well (i had the RHF5 and my next adventure will be with a garrett GTB VNT turbo), so its up to you to find one that suits your needs, bearing in mind there isnt a huge amount of space behind the block so a relocation to the top of the gearbox and associated work would be needed (not sure how that would work out with the Master cylinder the other side on a european vehicle)
with a standard turbo the clutch may struggle with torque at higher BHPs mine slipped in 5th and 4th at 174bhp.
the exhaust was a limitation on mine as well even though it was decat, i upgraded to a 2.5inch straight through made it lovely to get the power through with little restriction but for 170bhp max i feel a 2.25inch very free flowing exhaust would be adequate. The power was there on mine but the spool was MUCH better with the larger exhaust.
i had wanted to go higher BHP wise but the restriction on mine was the pump (OEM R65) and the rail pressure sensor, upgrades to these are an R70 (bosch part number 0445010021 ) from a 2.2HDi (its a straight swap) and an 1800bar rail sensor from the 1.6hdi
If you need a map for the engine management, then speak with HDi-tuning.co.uk as he did mine and i was VERY pleased with the price and results, other people will also be able to recommend other mappers.
I would suggest that with the increase BHP you look into a nice break upgrade, the GTi-6 (i think its the S16 on the continent) has larger rotors (283mm) and calipers with a much larger piston. you have a wider range of brake pads and can get the renault clio pads to fit nicely meaning they are cheaper than quality pads for the 266.
the rear brakes are suitable as they are all very very similar in size, only one version of the GTi-6 had larger rear pistons (if i am correct in my reading) but it was tiny and would make very little difference to the car overall so not really worth it
Find something that Fits, and use that as there is LOADS of room in and around the front bumper, but you will likely need slim line fans. SPAL make nice cooling fans.
Hoses, silicon and alloy i purchased from http://www.autosiliconehoses.com/ Cheap and nice quality.
as to configurations for the intercooler, Twinpass with both hoses coming through what would be your drivers side is slightly easier, as there is more of a gap on the gearbox side of the vehicle, or a single pass and run a pipe back across the top is also common, there doesnt seem to be a particular type that people use, as big as you want (there are some as large as the radiator itself on here for some of the builds)
You are more flexible with the positioning of the cold air inlet to the turbo as the M/C is on the other side of the car. if you have a look at my project thread you will see the cold air feed from the air filter comes across the front of the engine and then down under my master cylinder (drivers side, your passanger) into the turbo, and the high pressure from the turbo came out of the top of the turbo, along the back of the engine and across the gearbox.
Ideally you will need the inlet elbow from a 110HDi to deal with the Cold side into the inlet, this is the simplest to way to get the intercooler piping in, the inlet manifold itself is the same but the elbow bolts on
this picture has one with the EGR port cut off and welded (you should remove the EGR)- this one is from this forum Speak with Poodle or Jonny on here as they sell blanked ones for reasonable prices
![[Image: Pug406l-bendDE-EGR02.jpg]](http://s245.photobucket.com/user/Dum-Dum1986/media/200bhp%20project/Pug406l-bendDE-EGR02.jpg.html)
As for a boost controller, http://www.ebay.co.uk/itm/like/220537042109 is a good shout, i have one of these and it does the trick nicely..
Gauges, obviously TIM turbo and Stack etc are good, pricey but good quality, but its really uip to preference and how much you want to spend.
With regards to turbos, again it depends on how much you want out of it, 150 is comfortable with good intercooling on a standard turbo (if pushing it a little) but it runs out of puff around 3500rpm, GT20 series is a good upgrade for, GT2056s seems to be a common choice, IHI RHF4 and RHF5 seem to be popping up as well (i had the RHF5 and my next adventure will be with a garrett GTB VNT turbo), so its up to you to find one that suits your needs, bearing in mind there isnt a huge amount of space behind the block so a relocation to the top of the gearbox and associated work would be needed (not sure how that would work out with the Master cylinder the other side on a european vehicle)
with a standard turbo the clutch may struggle with torque at higher BHPs mine slipped in 5th and 4th at 174bhp.
the exhaust was a limitation on mine as well even though it was decat, i upgraded to a 2.5inch straight through made it lovely to get the power through with little restriction but for 170bhp max i feel a 2.25inch very free flowing exhaust would be adequate. The power was there on mine but the spool was MUCH better with the larger exhaust.
i had wanted to go higher BHP wise but the restriction on mine was the pump (OEM R65) and the rail pressure sensor, upgrades to these are an R70 (bosch part number 0445010021 ) from a 2.2HDi (its a straight swap) and an 1800bar rail sensor from the 1.6hdi
If you need a map for the engine management, then speak with HDi-tuning.co.uk as he did mine and i was VERY pleased with the price and results, other people will also be able to recommend other mappers.
I would suggest that with the increase BHP you look into a nice break upgrade, the GTi-6 (i think its the S16 on the continent) has larger rotors (283mm) and calipers with a much larger piston. you have a wider range of brake pads and can get the renault clio pads to fit nicely meaning they are cheaper than quality pads for the 266.
the rear brakes are suitable as they are all very very similar in size, only one version of the GTi-6 had larger rear pistons (if i am correct in my reading) but it was tiny and would make very little difference to the car overall so not really worth it
Given the choice between Niall and the sheep. I would choose the sheep!
/Toseland
/Toseland