As alot of people know, in its later days, the XUD was having some serious issues with heat / the head, and eventally ended up dropping two precups out the head, into the bores, which obviously wasnt to good, and marked the end of the XUD for me, for now at least, was happy with what I had done,  only really missing a power run to find out what it was really making, but I guess ill never know now!

Anyway, moving onwards and (hopefully) upwards, I have decided to embark on a new project, something ive been keen to have a go at for some time, and now just seemed the right time. Ive decided to basically go down the DI (Direct Injection) route, (like ve tdi’s etc) instead of the IDI system as before, now as you know, Peugeot never built a true mechanical DI motor, as they jumped straight to common rail in 1999, so I have decided to convert a newer “HDI” motor, back to mecanical injection, by retro fitting an older VE injection pump, mech injectors and other bits and bobs…

Have decided to go down the 16v DW motor route,  for several reasons, but all will become clear in time… am planning on running a sequential twin turbo setup, with the small turbo being a VNT, which should give me lots of driveability, and still some serious flow for future tuning, I say future, as I have no plans on the big turbo doing anything much until the engine is much more settled in / under control, but that’s the long term plan…

So got the project underway by fully rebuilding the bottom end, including fitting the forged conrods out of my old XUD, balancing the bottom end, skimming the deck, honing the bores, and rebuilding it with new seals / rings / bearings all round.

Big thanks to everyone thats been following me / subscribed to me,  Im hoping that 2012 will be a year of some interesting new project, so stay tuned and check back for more, the latest project should be shaping up right after the new year!

Had lots of intrest in the car, and big thanks to CARLOS who took most of these photos,  I live in your debt!

Thanks to everyone, had a fantastic weekend away!

Starting by removing the hub

Then pressed the old bearing out:

Empty hub:

Replacement bearings, genuine!

Forgot to take pictures of re assembly, will do when i do the other side!

Fans mounted…

Intercooler back on…

Also resealed the cam cover as it was seeping oil down my clean block and singing on the manifold!

The idler pulley failed on the superchargers drive belt, and caused the belt to wrap up in the typical XUD style around the cambelt….

So had to strip it all down and put that right, and redesigned the belt system, to give more alternator contact, to stop is sqeeling, and to try and strengthen it…

Stripped the charger off….

And proceeded to weld up a new lower bracket with a pair of idlers, meaning the belt goes around the entire alternator to stop it squeeling, and a second idler for clearance / to stop the belt flapping hopefully.

Have had to modify the slam panal and the headlight, neither of which have been finished yet, just cut roughly to get clearance, will remove again to finish it neatly.

Then rebuilt the new injector pump / painted that up and put that on, along with cambelt etc..

Then started putting the alternator / PAS pump etc on, cant finish as im waiting for my supercharger brackets paint to dry….