Paul's estate mk2 - air intake on

[Paul_13]

That's how f*cked the turbo is

[Paul_13]

Got some where to take the head to, Roe automotive engineering in fleet

[Paul_13]

Looking good on the oil feed front

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Size comparison photo

[zx_volcane]

noice, looking forward to seeing this on the go

[Paul_13]

I looming forward to driving a car that doesn't sound like a police siren mixed in with a squashed frog

[Paul_13]

Just sorted the oil feed and return pipes.
I've figured what to do with the actuator, use a gt15 actuator but relocated and mounted the same way I did my td04

[Paul_13]

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Held on by one bolt but I've had a good pull at it and it's not budging. Bolts loctited in and the end of the bracket is kind of wedged against the oil feed bolt

[mr_fish]

tidy setup.

Nice one. Look forward to updates.

[Paul_13]

Just looking at the standard turbo earlier and how bloody restrictive it is! It's a tiny unit as well, gt20 should make a fair difference

[Paul_13]

Well that's the 406 pipe, which will definitely not fit!



Planning on using this, it's built for the larger 2.2 hdi maf sensor and has a 3" cold air intake feed off the bottom of the box



That's a 2.0 hdi maf placed in the hole, just hoping the 2.2 has the same plug

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No point using this as it just tapers down any way. Going to try and run the largest air feed to the turbo possible. I know spacing is tight but I've got a route in mind and thanks toseland for the recommendation for materials

[Paul_13]

Picking up engine head on Saturday with new valves

[mr_fish]

That's a 2.0 hdi maf placed in the hole, just hoping the 2.2 has the same plug

It does indeed

[Paul_13]

Got the head back, lapped in the valves yesterday now time to do the rest

[Paul_13]

New valves in

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Rockers cleaned up and installed

Lost my black rtv so cant put the cam in

[Paul_13]

One rebuilt head ready to go on

[Paul_13]

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How I've left it for today

Down pipe is off

Just oil feed and return pipe off
Timing belt
lift head off

[Paul_13]

There's a lot more to these hdi engines to take apart compared to a xud or a 6

[Paul_13]

Really struggling to get the thermostat housing off, is there a trick to this?

[Frosty]

Really struggling to get the thermostat housing off, is there a trick to this?

When i took the 1 off the engine that i sent to you i loosened the coolant pipe that runs across the back of the engine and then it came off pretty easy. It seems to hold pretty well on the seal on the pipe that goes into the housing.

[Paul_13]

Gotcha, nice one

[Paul_13]

Rained off for today. Very close to getting the head off.

Just got to undo the top engine mount and undo the head bolts

[Paul_13]

Looks like someone has done the HG in the past unless they left the factory like that

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Only obvious sign the HG had failed

However

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The egr cooler/heater was full of mayo, I wonder if this was the actual cause of the Pressurisation

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Everything ready to go on

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Bit of a hold up, these will be going straight in the bin

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Oil feed and return lines on

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Got some funny looks lifting the head out, I was standing one foot on the cross member at the front and one foot on the scuttle panel

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Got a plan for the air intake

180 57mm > short piece of 57mm pipe > 57 x 70 reducer > 70 pipe > 70 90' > tee for oil breather > pipe > maf

[tim 306td]

This is going to be sweet. Giving me inspiration for mine as at the moment having one glitch after the other

[Tom85]

Well done for getting the head off complete with turbo/manifold attached! How was clearance - did you have to swing the engine forward a lot?

[Paul_13]

Not really, just removed the studs off the exhaust elbow

[Paul_13]

Nearly back together, couple of issues

Air intake is proper bodged for the mean while until delivery turns up
put a 60mm flexi pipe straight off the turbo and cut down the hdi air intake metal pipe. Works for the mean while

I f*cking hate the radiator designs on 306's, luckily I had an o ring from a 28mm pushfit cap, stretched it over and luckily it sealed

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Then oil appeared in the header tank



Where I lifted the head off loads of oil dripped over the block and I think some got in the water ways. Tried getting the majority of it out

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[Piggy]

Dish washer tablet flush ?

[Paul_13]

Used a rag to get most of it out, but yes probably going to flush it as some of the old coolant reappeared

[Paul_13]

Well it drives, need to get a map sorted for it.

MAF sensor has a HUGE paddy as there's too much sir flowing through

[Paul_13]

Just loaded the map up, big thanks to hdi tuning

Feels rapid

But there's a problem I'd hope that would go away when I loaded the map up, but I've f*cked something up during the HG change. I've got a horrible feeling I've buggered the flywheel why I was doing up the bottom pulley bolt.

I rev it hard and when it settles to idle it only runs on 3

Turn it off and on and it runs normal