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2.0 HDI Lexus 6 Speed Conversion

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01 Apr 2015 18:52 #141777 by OllieNZ

Paul_sterling wrote:

OllieNZ wrote: I'm in Oxfordshire so a bit far away. Good luck with it. I'd like to see one for the 1.6 110 HDI engine, they cop alot of flack but 90% of their issues are due to their emissions control systems.


My C2 is powered by the DV6 (1.6 Hdi) 110bhp engine. had it 7 years, 80,000 miles since new (I bought it new) and it is brilliant.

Paul.

I hope yours doesn't have the same emissions control system as my 54 plate 307, they start playing up around 70-80k. I had mine mapped out, cheaper than fixing it and no future hassles.

Keithy wrote: A 1.6 16V? would have been fine....same bellhousing bolt pattern?

I should be outside making moulding boxes (flasks) Naughty aren't I

Afaik it's completely different to the previous generation hdi's

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02 Apr 2015 06:59 #141790 by Paul_sterling

OllieNZ wrote: Afaik it's completely different to the previous generation hdi's


very true Ollie,

the base platform for the DV6 was a joint venture between PSA and Ford, new from the ground up, so its not directly interchangeable with the existing 2.0HDi engines.

but, with a suitable bellhousing, it is a smaller engine, so fitting shouldn't be an issue.

the later Euro 5 onward versions are only single cam 8v, better useable performance, and a cleaner running engine, harder to dial out the aftertreatment system though.

Paul.

Paul Sterling
2015 Jimny SZ4+, 1996 Toyota Hilux Surf, 2014 Mercedes W204 C-Class
(previously) 1994 Vitara JLX SE 16v, 2000 Vitara JX 8v

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03 Apr 2015 20:58 #141862 by Keithy
Finished the moulding box for the bellhousing today.....it's huge! :D



Just behind it is the start of a lost wax pattern for an inlet manifold for a 950 V twin dirtbike...not mine sadly!

While the glue is drying on the box I finished another drawing for the turbo outlet as the existing outlet is for the transverse install in the Pug.



I have no facility at home for casting iron so I'll get the patterns finished and check the fit with an Aluminium pour, then drop the patterns off at a local foundry for casting.

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03 Apr 2015 21:03 #141863 by Paul_sterling
Great work Keith!

Paul.

Paul Sterling
2015 Jimny SZ4+, 1996 Toyota Hilux Surf, 2014 Mercedes W204 C-Class
(previously) 1994 Vitara JLX SE 16v, 2000 Vitara JX 8v

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03 Apr 2015 21:24 #141866 by Keithy

Paul_sterling wrote: Great work Keith!

Paul.

Cheers Paul!

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08 Apr 2015 20:37 #142131 by Keithy
Finally managed to try the pattern for the turbo housing.....Made a new one as I wasn't too happy with the original.

Pictures speak a thousand words so it starts on the router table and ends on the engine.

Just need to call at the foundry and then I can concentrate on the gearbox/ECU side.

After £150 on sand no more funds until next month.























The following user(s) said Thank You: Paul_sterling

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  • Placek
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08 Apr 2015 20:40 #142132 by Placek
Replied by Placek on topic 2.0 HDI Lexus 6 Speed Conversion
Wow, that's impressive!

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08 Apr 2015 21:18 #142137 by Maze
Very impressive the work you made so far!!!!!! ;)

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09 Apr 2015 20:52 #142207 by Keithy
Cheers guys!

Plenty of stuff to do yet when time and funds allow :)

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  • panosd
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07 Jun 2015 13:29 #145595 by panosd
Replied by panosd on topic 2.0 HDI Lexus 6 Speed Conversion
You are the man. Keep on going.

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07 Jun 2015 21:41 #145630 by Keithy
Just back from Strata Florida with the Jimny.....having a fantastic weekend of camping and laning=nothing getting done on this project!

The timescale for this project is to have the engine fitted and sorted by April next year in time for insurance renewal.

I have a couple of weeks in July where I'll be at home so expect some progress then.

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21 Jul 2015 20:44 #148213 by Keithy
A little progress......I've got the turbo outlet back from the foundry.

Drilled and machined......I need to get the gearbox castings made and fitted so I can start the electrical work soon.

Not much free-time at the moment.

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