darrenjlobb's Adaptronic Managed Compound Blown Derv Bus Build

[darrenjlobb]

Promised an update , so here we go!

Have been working on this in drips and drabs, so its all a bit out of order etc, but will do my best to update on most of the bits I have been working on, which mainly consists of the fuel system, cooling system and air charge system.

Starting with the cooling system, first step was to size up for a rad, was unable to use a stock sized rad this time round as the turbo have moved forwards for better clearance, which meant that the top of the rad / top rad hose would line right up with the intake of the turbo, making it impossible to route any hoses, I also wanted to move my air filter down onto the front clip rather than having it sat up on the chassis leg, mainly for access to clean cold air, but also because it never fitted right up the top, and was always a bit of a bodge!

So after some searching around settled on a rad from a Ford (oh dear!) albeit an aftermarket ally one:



Also note the new lower rad hose, which after realising I couldn't use the stock rad had to have its connector axed off, but had already ordered it when I realised I couldn't use the stock rad!

Drilled new mounts, and made new rubber centered brackets for the top of the rad, and fitted it to the car, perfect fit for what I was after:





Then re-mounted the expansion tank, same as I was using on the MTDI, only this time put rivnuts in the holes, so easy to bolt in / out without having to drop wheel / hold little nuts in the wheel arch with one hand etc!







Then pretty much proceeded to just plumb it all up, using new hoses all around, will also note everything is in black this time around, guess I must be getting old, but prefer the look of it these days! Used the same external stat housing I made up as before, and air bleeds all as before other than a slight re route etc. Havent put any coolant in it yet, as want to wait until engine is wanting to run before I do, just incase head is breeched at all, don't want cylinder full of water for a few months before I notice!


Moving onto fuel system next,  had a few basic things in my head that I wanted to achieve, firstly was to remove 100% of the factory peugeot fuel system (which I had already done before painting the car). Secondly I wanted to mount the lift pump and filter head under the car so that it was out the way in the engine bay, and easy to get at. 

Basic fuel system in essence is basically a 044 lift pump from the tank, up to a swirl pot in the engine bay, from which the CP3 can feed from.

First step was to get swirl pot mounted up, item I ended up using:




Original plan was to mount it on the drivers side chassis leg, but sadly just not enough room, looked at dropping a section down, but then had problems with charge pipe clearance, so decided to mount it in front the engine in the end where there was much more room. So just made up two brackets, drilled and tapped them, allowing the swirl pot to bolt straight down to it:



Will also note the -8 fittings on the swirl pot, As before I am trying to use these style fittings on everything where I can, as find it a much easier and cleaner way to route pipes around the car. 

So next step was to get the  CP3 feed and return adapted to take a -8 fitting, So bought a pair of M14x1.25 > -8 adaptors to fit to the pump, had to make slight mod to one to fit in the recess:



And fitted:




Then seems to be a lack of photos of next step, but basically then routed the feed / return hoses from swirl pot to fuel pump, including an inline temp sender on the feed return so I am able to monitor fuel temp in the ECU.

Moving to the back of the car, I wanted to modify the stock fuel pickup to take -8 hoses, and also be much less restrictive, so removed the fuel pickup unit:



Cut off the standard fittings from both sides, over drilled them to 1/2" and fitted a pair of 90 degree tank fittings with dowtys to seal, even left in water over night to be 100% it was sealed fully, as have had a fail in this department before! But it was all good, so proceeded to fit some 1/2" tube to reach to bottom of tank, with couple mm clearance. Both send and return to reduce air inclusion:





And fitted to the car with hoses hooked up:




Next issue was fuel filtration, very much hate just about  all standard Peugeot CR items, messy, fiddly and frustrating to change in just about all cases, also wanted to run a 5 micron filter to help protect my pump / injectors. So settled on a industrial filter head and filter, was going to use a Deere head and filter, but was less than impressed at the price of the filter head at my main dealer, so promptly changed that plan! Overall flow looked a bit poor in the filter head, so drilled out each inlet / outlet within an inch of there life, and then piped it up to use both inlets and both outlets to ensure I don't create a restriction:




Standard item Bosch 044 with a cleanable pre filter on it to keep the major crap out the pump / clogging up the final filter (which is easily done at 5 micron level):




Drilled and rivnutted some mounting holes under the boot floor:




Cut sheet of ally and test bolted up:





Then bolted everything up, changing fuel filter is now going to be a breeze, and no mess involved!




And a photo of the engine end plumbed up:




Then time to drop injectors in the head.  Injectors are basically a stock 16v item from bosch, with larger nozzles fitted. I have then had them extensively flow tested by a professional diesel company (I have no means of testing CR injectors to this level) to give me a full flow table (duration vs rail pressure) to allow me to setup the injector calibrations in the ECU correctly.

Started by re fitting the PSA mounting hardware:




Then bolted them to the head. Have bought new injector lines for the injectors, and also had to custom bend a new line for the pump, as obviously much longer / different location to normal!





New line fitted to pump, had to remove swirl pot for access to fuel rail etc:




And all plumbed up, just the returns to finish off:




Re-fitted the oil cooler, after welding new fitting to one side as existing one was leaking / half sheared off! (Mocal coolers built like utter crap imho!):




Then bend up a new bit of line for the EMP gauge cooler and fitted it to the manifold, and plumbed up the gauge:







Then fitted turbo acuator, PWM activated hella unit, with oem linkage, just had to modify mounting bracket slightly for clearance, other than that bolted right on:





Then started on the charge pipework, wanted to run air temp sensors on both stages of charging, as well as raw intake charge, so started by welding plates on the effected boost pipes, and drilling  / tapping them for map sensors and air temp sensors:







Then mounted a plate up for the reg valve for the external gate so I can control that from the ECU also, along with the MAP sensor for the first stage of charging, this being a 3 bar sensor, and the main map sensor on the intake being a 5 bar sensor.





Then started fitting up all the hoses etc to the car:






Interchoocher back on:








Which largely leaves it nearly mechanically finished, Next major job is wiring the engine / car up, and testing some systems out etc.

Thanks for reading