td163's Clean Moonstone HDI Build

[td163]

Hi all,

Please be nice I'm a n00b & have owned my first HDI for about a week now. The project will be a bit bland at first as I get all the boring bits out of the way like replacing parts & tidying bits and bobs up to make way for tuning. I have the vision of a aggressive looking stage 3'd car .

The car is a 2001 Moonstone HDI Phase 3 with only 83k miles on the clock & a very clean body to match! when I say clean I am talking about 4 small paint chips, 1 small bonnet dent & odd minute stone chip on the bumper on the whole car which is pretty amazing for a 14 year old car, it really is a credit to the last 2 owners. I will be taking my time with this project and doing it all properly with quality parts without compromise which I have had to do with some previous cars due to the cost of tuning them was very high but it doesn't help my OCD nature at all .







Old & new





I have been off work this week so got quite alot done up to yet....first thing I did was a mini service which consisted of a Oil + Filter change and a Genuine Air Filter, went with Total 9000 Fully Synth as it was recommended over and over on the forums with a OEM Purflux Filter & a Citroen Air Filter:





I got some engine cover mounts and clips from ebay, nice and cheap and do the job well





Picked up some floor mats in grey as the interior looked a little bare without any



I also got some Redex Diesel Advanced and put in a tank of VPower just for peace of mind....still not sure if its all hyped up marketing but still  


Part 2--

On ignition the heater blower and the small fan used for auto climate control were quite noisy and although they worked fine the noise annoyed me. I removed the heater blower & greased it up to try and quieten it down for a while which worked and didnt....I just replaced the small overhead fan as the bearings were shot.



Ooops :/





Small fan that was dead



Having a nosey under the car making sure there are no nasty leaks I spotted a random pipe just hanging down at first it looked like it have come of something but after asking on here I found it was the fuel drain pipe. I decided to cut it down a little and secure it neatly so it wasn't just dangling there.



Removed the 'sporty pedal feel' spring from the clutch pedal in hopes it would make the pedal lighter but it did naff all in reality lmao but it turned out the spring had already sheared in 2!!!



Finally I found out my Crankshaft Pulley is FUBAR'd but I have ordered a uprated solid replacement from Febi & new drive belt to go with it, got a touch up paint pot, Total Gearbox oil & some dash bulbs coming soon and then it will be nearly ready and in great shape.

It will get more interesting I promise

[Eeyore]

Looks like its coming along well! Looks fairly mint so best of luck with it! Get it remapped! Its super cheap and easy and transformers the car. makes it more efficient too!

[dhdcdarchy]

Kept yourself busy this week then mate?
Can't wait till I have the time.

She's looking sweet,
what's next on the list before you get to the good stuff?

[td163]

Looks like its coming along well! Looks fairly mint so best of luck with it! Get it remapped! Its super cheap and easy and transformers the car. makes it more efficient too!

Thanks I am happy with the progress up to yet That is first on my list me and dhdcdarchy below are having a nip over to Dervtech sometime before FCS to get mapped up lol I will hopefully have a decat by then so can go stage 1+ I think it is and he wants a solid stage 2 map I think.

Kept yourself busy this week then mate?
Can't wait till I have the time.

She's looking sweet,
what's next on the list before you get to the good stuff?

Only had tuesday and today but got some good stuff fixed. I cant either mate when we get better weather days we will have to get tuning together.

Whats left....its looks alot but it shouldnt take too long I hope:

Sort out why the drivers seat rocks (sure its runners)
Clean/grease up that fan connector that can set the car on fire :/
Re-grease the heater blower one last time
Possibily get aircon working/gassed up
Get that f**king fly out my headlight
Sort Passenger seat rattle
New drivers front tyre
Tighten handbrake cable
Re-do Headunit wiring

And a few more things to buy like get PS Fluid & Brake fluid redone, Repair rear spoiler & Wiper arms, some new CV boots.

Nearly there lol.

[dhdcdarchy]

Sounds good!
Yeah man after this month I've got some nice spare time so let me know and we'll get stuff done.

While you're getting the fly out you might as well spray the insides black ;D
Next few weeks I'll be ready for remap so get that exhaust sorted!

[Poodle]

Nice to see someone going about this the right way round, look forward to seeing the car develop bud. Good luck keeping the aircon if you're going stage 2, it can be done, but it's bloody tight lol.

[Piggy]

Jealous of your body

[td163]

Sounds good!
Yeah man after this month I've got some nice spare time so let me know and we'll get stuff done.

While you're getting the fly out you might as well spray the insides black ;D
Next few weeks I'll be ready for remap so get that exhaust sorted!

Yeah man! Looking forward to it. I found a nice decat pipe on eBay for 50 quid I think from turbo to center pipe.

Nice to see someone going about this the right way round, look forward to seeing the car develop bud. Good luck keeping the aircon if you're going stage 2, it can be done, but it's bloody tight lol.

Thank you mate it that because of the front mount pipes?

Jealous of your body

*tried to think up a whity comment and failed* hahaha but thanks Bro for the kind comments.

[Poodle]

Yeah, there just isn't the room.

Bear in mind you will struggle to get an mot without a cat box in place.

[Matt-Rallye]

Lovely looking HDi looks like the perfect shell to start with

[td163]

Yeah, there just isn't the room.

Bear in mind you will struggle to get an mot without a cat box in place.

Looks like that will have to come out then..... Tbh the fans done spin when the button is pressed so think it's dead anyways lol. I have a friendly MOT guy that's helped me in the past luckily as the Subaru had all 3 cats removed hahaha.

Lovely looking HDi looks like the perfect shell to start with

Thank you mate

---

Little delivery turned up today bargain at 21 quid for 4L

[Poodle]

Fair play, you should be sorted then. Don't put all of that box oil in, it only takes two litres lol.

[td163]

Fair play, you should be sorted then. Don't put all of that box oil in, it only takes two litres lol.

Thats good to know have not yet researched about the capacity. Cheers mate.

---

UPDATE-
These turned up the other day and attempted to tackle it but failed badly

Febi updated solid (a little rubber in there still) revision 2 pulley



All was going well until the Crankshaft Pulley bolt....it would not budge at all even with my brand new 1000w 450nm impact wrench!



I also tried the wheel breaker bar with no avail....think i am going to have to get a garage to break the bolt off with air impact gun. I did put the new belt on while I was putting stuff back together though as the old was was well past it.....



To be continued.

[td163]

Its been a while so thought i'd pop up an update...been fairly busy amassing parts and slowly beginning to tune the thing!

Due to the rear wiper being knackered I just decided to remove it fully and blank it off, not to everyones taste but I think it suits the car more



EGR Blank waiting to go on that dhdcdarchy kindly gave me!



As I was wanting to lower the car I did not want to put lowering springs on tired front shocks so decided after looking around to get some OE spec Bilstein B4s front and back which are happy with 40mm springs. I got some generic 40mm springs from Online Autosport as they dont seem to bad from the reviews & I dont mind a harsh ride i'm used to coilovers anyways.




Having to listen to the ticking coming from the injectors under load constantly after just 4 weeks of ownership I had enough and shelled out for some uprated '076' injectors which were meant to be quieter.



1 out of 4 old injectors removed after alot of wiggling and bloody knuckles . The blue paper towels are there covering any fuel openings from dirt.



After old injectors were removed there was alot of muck which had to be cleaned out.....



After getting the 076 injectors fitted it did not help the ticking noise I spent the next few hours moaning and threatening to sell the car (everyones been there im sure! ) due to wasting nearly £100. I decided to look further into quieting it down and I decided to try 200ml of 2 stroke mineral low ash oil mixed with a full tank of diesel. Low and behold it actually helps a noticeable amount, don't get me wrong it doesnt make everything disappear but it quietens it down alot and sounds alot smoother I would definitely recommend it.


.........

---

........

Parts slowly piling up...motivation is needed plus a job not working 45 hours weeks constantly would be ideal lmao.



Did some head-unit wiring tidying up on my relentless mission to stop rattles




I have saved the best to last I popped over to dhdcdarchy's to pick up a exhaust system he had spare from his old silver HDI that will soon be scrapped and ended up coming home with a set of Cyclones, Laguna splitter & the exhaust hahaha





I fitted the wheels and splitter straight away (the exhaust needs welding so has to wait)

Wheels on-


Splitter-





THATS ALL FOR NOW FOLKS!

Coming soon, fitting the suspension, fitting the exhaust, rear spacers, EGR delete & Pro Steve Stage 1+ map .

[Frosty]

Coming along nicely chap, good work.

[RetroPug]

Looks really nice!

[7057sam]

Looking great

[Jonny81191]

Looking good, nice to see an honest car being given a new lease of life

[td163]

Thanks guys for the kind comments I'm really enjoying it! I am really surprised how much the cars look changed when putting Cyclones on they match the cars body better I think.

What would you guys say is a solid stage 1 for the HDIs? in my head I have full exhaust system, uprated induction (or is stock airbox good?) and a remap. Have I missed anything?

[Jimbo]

Id Personally leave standard airbox, and blank the egr before its mapped then pro steve can map out the egr all together

Nice car btw, liking the work so far

[td163]

I have found that on most cars that the design of the stock air boxes do not cause any restriction until you get very high up in the tuning. Glad its the same with the 306, guess a panel filter is on the cards then.

I will make a note to get that done mate, I saw a thread on here but wasnt very explanatory what has to be disconnected EGR wise.

[bashbarnard]

Well this looks very clean. Don't know how I've missed it. Good to see you didn't sell it. We've all been there you're right.

[toseland]

the issue with the airbox on the HDi i found was the small cold air inlet, being restrictive..

make that larger and everything gets better

[MY95]

Do you mean the end of the snorkel nearest to the edge of the front grille Toseland? Sure someone said it was best leaving it how it was and not cutting it any larger

[Poodle]

If you cut holes in that trumpet you lose the ram air effect at speed.

[td163]

Bit of a long overdue update guys, a bit has happened since. Shortly after fitting the alloys & splitter I took advantage of Pro-Steves offer for 306oc members and got a stage 1 remap to roughly 120bhp and 199 FT/LB, as everyone has said it makes the world of difference and Steves service was epic.

Playing around with the mapping software-


Due to having some bulbs out in the speedo cluster I went about changing them all for some new OE spec ones. I didn't fancy changing the colour this time around though and I changed all the bulbs that were used for lighting up the cluster as I didn't want any hot spots as that would be more annoying than having them out!



I know it does very little but wanted to ditch the paper air filter and popped in a Pipercross panel filter which I know will be perfect for my end stage 3 goals. I got rid of the 206 GTi gear knob and put on the OE 306 black one which I prefer and found a gel domed french flag I stuck on but unsure if I like it yet.




I picked up a drivers side engine mount also to go with the gearbox one I have sat in my room to fit soon. Hoping this will stop the rocking motion going on and off acceleration.



I decided to disable the EGR but due to my HDI being the later model it came with another part called an Air Doser which had to be disabled. I have unplugged both these & plugged all the pipes. I do have a Inlet blank to fit soon just in case its stuck open a little.



Did a normal oil change this time for the 10w40 semi synthetic stuff recommended by Peugeot & a gearbox oil change.



The injector rattle is still driving me mad even with using the 2 Stroke & changing the injectors so decided to try something new and bought some professional sound deadening material. I put some under the engine cover and also wrapped some around each injector I did have high hopes for this BUT as usual it did naff all! so ripped it all back off.




Finally I bought a revised version of Lynx Power Engineerings Billet Crank Pulley. I know I had only replaced the pulley a short time ago but it started making noise again. The pulley is a think of beuty and came powder coated in a matte grey, seems they have made changes to their design. Best bit is it weights less than half than other solid OEM spec pulleys!!! big thanks to Rich from Lynx for sorting me out.





Final cheeky side shot




Thanks for reading guys!

[Matt-Rallye]

Wow that does look clean! great job fella keep it up

Reminds me of mine.. i really miss this faithful 200k babe :



More commonly seen like this though

[MY95]

Looks really clean mate! 5dr HDI friends aha
Whats your next plans then?

[td163]

Wow that does look clean! great job fella keep it up

Reminds me of mine.. i really miss this faithful 200k babe :



More commonly seen like this though

Thanks dude! Yours looked really clean also from the pictures. I think this colour is forgiving lol.

Looks really clean mate! 5dr HDI friends aha
Whats your next plans then?

Haha thanks dude. Next I want the suspension setup on and the exhaust system. After that stage 2

[td163]

Recently I have gone about getting my exhaust system fitted and built.




I fitted my de-cat downpipe & race tube on the driveway with decent success. But the first bolt I attempted to remove snapped completely! I managed to remove and replace it, fingers crossed that didn't set the tone for the whole job.





All sorted!



Rubbish soft Cyclones



I then popped into Custom Pipes in Doncaster for a custom made backbox, high flowing and a nice round tip that fills the cutout well I think. Its slightly angled to the side too which I like....makes it a little different.









And finally gave it a nice wash






Thanks for reading.