Peugeot 205 XUD7 to XUD9 conversion.

[stonyray]

Right, I (after too long with Mondeo TDCIs, Primera dCis) am returning to retro motoring,

EDIT 2: Engine is goosed, should be sourcing an XUD9 shortly.

Long story short I am collecting (hopefully) a head gaskety 205 Turbo Diesel, when replacing the gasket I want to use a good quality one. I have always rated Payne over the likes of BGA & FAI. Any uprated options for the XUD7? My google FU is weak.

EDIT!:

I have the car now its really quite clean, got it into the workshop and turned it over, it spins over fine. Cam is turning, diesel is flowing. nothing not even a cough of it trying to fire. Sprayed some easysart into the intake and nothing for about 5 deconds the a loud pop as the easy start explodes out the inlet in a cloud of grey smoke?

Whats going on do you reckon? Timing way out? Burned/broken valves? I am confused TBH. I have given up on it for tonight its rather late. Will pull the head off tomorrow and investigate the cam and bores.

[jasonj]

Get a multi layer steel gasket. Available from most good motor factors. The XUD has a few options on thickness which is denoted by notches on the end of the gasket. You need to remove the old one to check before ordering a new one. Obviously if you skim the head you need to allow for that. DON'T refit the head without having it skimmed and tested. If the gasket has gone you can pretty much guarantee the head is warped to some degree.

[tdipd]

on xud9's I only use a steel multilayered, supplied by the machinist at a good price. On the one occasion that I skimped and went for a cheap one, the gasket leaked immediately

[stonyray]

edited my 1st post as I now have the car

[tdipd]

Def check the timing belt marks as a start. Particularly the mark on the diesel pump, as it doesn't sound like you have valve and Pistons smashing.

On the xud9 it was always easy to get the timing one tooth out, but even then it would start but run like a bag of spanners. Injection timing can be advanced or retarded by loosening the mounting bolts on the pump and rotating the pump back and forth too, if it needs fine tuning.

[stonyray]

That makes sense, it turns over smoothly and with the rocker cover off you can see the valves going up and doon.

Timing marks easy to spot?

[tdipd]

8mm bolt locks camshaft pulley
8mm bolt locks fuel pump
Remove starter motor and poke an Allen key through the wee hole to lock the flywheel at tdc.

If they don't line up you have an issue

There may be indentations on the pulleys too for putting on a new belt with marks, I can't remember for sure, but it's likely

[stonyray]

awesome, I'm off to start mu build thread in reader rides.

[ChasR]

I was about to say, timing up an XU engine is relatively simple as described by TDi PD.

[stonyray]

This is it now.

And when I first pulled it off the truck.

[tdipd]

The engine buggered?

... Get a xud9te in there! (With boost cranked up, and larger head in the pump)

[stonyray]

The engine is curse word! Its blown a chunk out the block between 2 and 3?!?! Never seen anything like it before.

XUD9TE fit in no messing no modding? Will the 205s BE1 bolt up to an XUD9?

EDIT: I know the 306s BE3 is stronger and better but I need to get the car running and out of a mates unit asap.

[Anthony]

205 'box will bolt up just fine, but you'll need to use the 205 clutch and release bearing as well to match the BE1 type clutch fork/lever (306 uses a pull-type clutch, 205 a push-type clutch).

Was the old engine a 1.8TD? If so, it should all bolt up as that uses a 215mm clutch as standard. If it was a 1.8 N/A then it'll be the smaller 200mm clutch and won't bolt upto the 215mm flywheel on the 306 engine, and realistically won't cope if you start whacking up the fuelling and boost either.

You sure it's a BE1 (lift up reverse next to 1st) btw? Should be a BE3 at that age (reverse below 5th)

No significant difference in strength between the various 5 speed BE 'boxes btw. The diff internals are slightly beefier on the later ones, but that's about it.

[tdipd]

Can't help you with the gearbox questions sorry, looks like Anthony has it sorted though.

You likely had a thrown conrod, it's known as 'a leg out of the bed'.... It happens on some phase 2 306's, was always told it happened those with 'DHY' in the chassis code.... I don't know if there's any truth to that. Never heard of it on a xud7.


try to get a 1.9td with a bosch pump, it's the more tunable one.


ps. if you need new timing belt idler and timing belt tensioner wheel for an xud9te, then i have them for sale on ebay. also have a new 'throttle' cable there. Had them in storage for years, forgot about them til recently.

[stonyray]

Anthony it is a TD so I can use the 205 clutch which is sweet.

Erm it may be a BE3 actually I think reverse is below 5. It is a 1995 model.

[stonyray]

Oh and I've just noticed I put hole in the block. Weirdly its on the inside of the head between 2 & 3 not the block.

[welshpug]

I did a similar conversion a few years ago, one thing I would say is that if you do use a 306 engine then use the 306 gearbox as well, the 205 ratios are quite short.

As Anthony said the easiest way to sort the clutch is to use all the 205 stuff, i.e arm and shaft release bearing and clutch assembly, good idea to bung a new pair of bushes in whilst you're at it, and note the colour of the bushes, there are yellow and white versions, yellow should be on shafts that are stamped with a J on the top (the fingers for the release bearing are a different length and the bushes alter the offset)

You will need to swap the 205 diff into the 306 box, as the planet gears in the uprated diffs are larger the 205 NS shaft will not slide in fully, and can leak on the oil seals, in worst cases can bottom out the inner cv.



Good thing with a 306 XUD9T is they use the same turbo elbow as a 205 so the downpipe bolts straight up.

[tdipd]

Aug 18, 2015 17:54:41 GMT stonyray said:

Oh and I've just noticed I put hole in the block. Weirdly its on the inside of the head between 2 & 3 not the block.

strange one, only thing I've had which was slightly similar was when a pre-combustion chamber fell out of the head on my 306,gouged the shat out of the head and mangled the piston and bore! .... and weirdly the engine still ran! sounded like a 100yr old tractor though!


I did go through 4 engines in that 1 car though haha, they were cheap as hell and easy to swap though .

had the old garret T2 wound up to 26psi (was still on the top mount intercooler )
injection timing advanced
ground down boost compensator pin
bigger pump head fitted
max fuel cranked
and just a middle box exhaust

[stonyray]

I will be using the 205 gearbox as the engine I have sourced has no gearbox. However I will probably look for a 306 box. Funds are tight atm as I have 3 other cars and need to sell 2 of them. Alas it's all modern tat.

are there any problems with the top mount intercooler in the 205 bay?

[tdipd]

I believe it does fit under the bonnet, but the 306 under bonnet lining directs air to it, the 205 may not have this. The engine will still run grand, just don't turn up the boost as the intercooler will be ineffective.

options would be to:
buy a bonnet from an automatic 205 (its humped in the middle)
raise the bonnet with spacers (yuck)
or fit an inlet manifold from a 406 xud9tf, which will allow to you make up a custom front mount intercooler setup


if your 1.9td has an egr you should think about removing it while the engine is out. I just welded up the holes with a big washer in the middle