Goce's 06 twin turbo diesel peugeot

brino

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Great clean-up.
Nice too see no other nasty surprises!

Thanks for all the high-quality photos.
I know what a pain it is to stop every few minutes, clean your hands so you can pick up the camera, get the proper view, focus and light, and then take the time to post them here. It is appreciated!

-brino
 

Downunder Bob

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A great write up, I'm glad it's not me I'd have lost patience days ago. Actually I hate small engines I'm used to ships engines.

You'll have to be very careful when rebuilding it,you won't want to have to do it again.

Keep up the good work

Bob.
 

GoceKU

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that'll be a fabulous engine and car once you put it back together. You'll have to be careful that people in your neighbourhood don't think that you've suddenly become royalty or a drug dealer :)
Haha, here is a man who clearly hasn't been in central europe (balkans). Here is a whole different world, people around here are clever, they don't take you at a face value. They will talk to you and find out are you acting or are you for real. So no worries there. To be honest i'm not the biggest fan of its styling, but the driving dynamics and ride comfort make up for it.
 

GoceKU

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reat clean-up.
Nice too see no other nasty surprises!

Thanks for all the high-quality photos.
I know what a pain it is to stop every few minutes, clean your hands so you can pick up the camera, get the proper view, focus and light, and then take the time to post them here. It is appreciated!

-brino
Thank you Brino.
I don't mind taking the photos i use my phone and i have a heavy duty cover over it so i'm handling it with dirty, greasy hands. Posting them and writing the threads takes me awhile and i often make mistakes mainly because English is not my first language. It some time helps me to keep a timeline when and what have i've done, I also hope it can inspire and help others.
 

GoceKU

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When everyone is running around buying food because of the coronavirus i'm buying car parts. I bought me couple of jugs of engine oil, some antifreeze, two head gaskets, oil pan gasket and couple more seals and some loctite. The parts prices on this engine are insane in fact what you see here cost me more than i make in month.
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GoceKU

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Today spent a lot of time cleaning and painting the engine block i clean the entire block with gasoline in a spray bottle, wire brushed couple spots and left it to dry. I want to paint the block to enclose the rust on the outside also to make it look better. After looking at the paints i had on my shelf i did not like any of them so i mixed me a unique color just for it. I started with a white base added silver and black to get this pearl color. I used a no:10 brash and painted the entire engine block. This took me entire evening i'll clean up the machined surfaces with a razer blade ones it harden. I'm sure it will not even be visible once in the car but i feel better when it's clean.
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Packard V8

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That's an amazing project you've taken on. Here in the US, cars such as that are routinely scrapped because our $125 per hour shop labor cost would add up to more than the car's worth.

The parts prices on this engine are insane in fact what you see here cost me more than i make in month.
Sometimes when a forum member in a far-off country takes on an engine project, I'd offer to help by buying parts here in the US and shipping them overseas. However, it's doubtful there are any parts for your Pugeot V6 diesel in warehouses in the US.

Keep working and we'll keep following along.

jack vines
 

GoceKU

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Today i begin assembly on the engine for the 607. Started with cleaning all the paint from the machined surfaces with a razer blade. Then i used some strong solvents to clean the main bearings, caps and the engine block. When i was cleaning i clean out the oil jets main cap bolts all 72 of them. Then i started with the oil jets torquing them i also used some loctite on them. Then i installed the crank bearings, they are made by Ford. Oil them and dropped the crank, i also used a little bit of silicone on the back oil seal cover. Then came time to torque all the bolts, i used couple of torque wrenches and angle gauges. I wasn't too sure about one bolt so i unbolted all of them and re torqued all of them again, by the time i was done my arms are hurting.
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GoceKU

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Today i've been struggling all day i could not find a piston ring compressor, most of the hardware stores are closed because of the coronavirus and the tool market is also suspended. I've called couple of friends and stopped by few mechanics, none of them has one that will fit. So for today i only could clean the bores i bend a brash so i can reach the bottom and oil them, then i clean off the oil pump install new gasket, new oil seal and installed it and torqued it in place. Surpassing the old oil seal did not have a spring in the back, it is a different design.
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Lo-Fi

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It's easy enough to machine a taper ring for fitting pistons. Assuming you have a lathe, of course, but that doesn't seem like too much of a stretch on a machinists forum :)
Its looking good. Did you figure out how to refit that crank sensor ring?
 

GoceKU

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Its looking good. Did you figure out how to refit that crank sensor ring?
I've made them in the past and i have couple of them but not for 81mm and i don't have any material in that size. Because of the coronavirus the steel places are closed, i'll borrow one for an hour just to slip the pistons in. For the sensor ring yeah i never took it off, took the crank with it assembled. And installed it just like that.
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Lo-Fi

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Oh brilliant! Glad there was a way around that.
 

GoceKU

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Today i installed all the pistons, and torqued them to spec. I borrow a piston ring compressor, and installed new piston rings, i did checked and file them to spec also clean the pistons, soaking them in diesel helped i also scraped out the rings grooves i did not take pictures of that because my hands were very oily last thing i installed was the crank pulley.
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The weather today was almost 20 degrees centigrade, so all the cars got washed i also pressure washed the radiator and oil pan from the 607, the pan come out clean, a bit worse on the outside. The radiator is a different story, i can tell the water isn't flowing in it but after leaving it to dry for few hours you can see all the oil that came out, i'll be doing a lot more cleaning, i price a new radiator and they are really expensive. In the meanwhile i continued assembling the bottom end of the engine, is install new gaskets, clean the upper oil pan oil pickup, dipstick tube and assemble them waiting for the lower pan to dry and get painted.
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brino

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after leaving it to dry for few hours you can see all the oil that came out, i'll be doing a lot more cleaning, i price a new radiator and they are really expensive
Is the oil from a secondary fluid cooler built into the radiator(power steering or transmission cooler), or was that oil in the coolant?
Forgive me if it's a stupid question, I know nothing about diesels.
-brino
 

GoceKU

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Is the oil from a secondary fluid cooler built into the radiator(power steering or transmission cooler), or was that oil in the coolant?
Forgive me if it's a stupid question, I know nothing about diesels.
Bruno, is not a stupid question. The oil is all around the cooling system, it is thick black engine oil, the radiator has no other cooler inside it, this vehicle has only one big engine radiator, no transmission, power steering cooler. The oil is probably from a previous blown head gasket or a bad oil cooler. Now i'm cleaning the oil cooler and investigation from where is all the oil in the engine valley.
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Lo-Fi

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Is the oil from a secondary fluid cooler built into the radiator(power steering or transmission cooler), or was that oil in the coolant?
Forgive me if it's a stupid question, I know nothing about diesels.
-brino
Actually a common failure mode for water>oil coolers. A mate of mine had a VW with an oil cooler built onto the oil filter block. Somehow it broke internally and pumped his cooling system full of oil! Looks like it's a classic head gasket failure that's let oil get where it shouldn't in this case, though.
 

Downunder Bob

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Why is it that european cars are so hard to work on and french definitely the worst.
 

GoceKU

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Why is it that european cars are so hard to work on and french definitely the worst.
Many of european cars are FWD and the engine, gearbox is in a confined place. But many because all car makers are using the same part in 20 models in different configuration which makes it hard to replace it if it goes bad. In other words part design for longitudinal engine configuration is going to fit in a horizontal engine configuration but it will be very hard to access or replace.
 

Packard V8

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FWIW, some diesels are designed with EGR coolers. Corrosive exhaust is piped through a water cooled radiator. Inevitably the corrosive gas under turbo back pressure eats through the cooler, pressurizes the coolant system and blows out all the coolant. BTDT; should have eliminated that system instead of replacing the cooler.

jack vines
 

GoceKU

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Yeah, Jack, this car has two electric EGR valves with coolers, i've tested them they are OK i plan to slip blok off plates to keep the engine clean on the inside. And from past expirence i know bloking them helps with turbo spool and in older cars makes them faster;)
 

GoceKU

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Today was a long day in the garage, i managed to clean off both cylinder heads and torque them down to the block, they are no joke to get them torqued. Just as i was washing my hands to finish for the day the parts store called, my timing belts have arrived i also bought new glow plugs for the ones i broke, and a new CV boot for the drivers side axle. Because of the coronavirus my city is getting shut down, i hope the rest of my parts and tires arrived, so i can finish this car. Also i'm getting a bit worried about the adapter for the engine stand i made, the engine is getting taller and heavier by the day, i'm not sure is it up to the task to hold all the weight i need to build it out completely to have less work in the car and heavy stuff like both turbos, pre cats, pumps, manifolds are heavy.
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GoceKU

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Today i continued with building the engine assemblies and mounting them to the engine, first on the list was the fuel, oil cooler and filter housing, i assemble them on my bench and installed a new oil filter. But did not mount it until i installed and torqued the glow plugs, then i mounted it and began assembling the thermostat housing i made on my lathe, you can see i cut and weld the pipe at 90 degrees and apply some 2K epoxy on the joints just in case. Then mounted the entire assembly on the engine. Next on the list is assembling the valve train which is very hard on the hands, i need to pump out all of the 24 hydraulic lifters, then i have to clean all the roller, rockers, cams, chen's, tensioners, oil seals, caps sprockets. My hands hurt just thinking about it.
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GoceKU

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Today was one of those days many small things and my hands hurt for real. I clean all 24 lifters, roller rockers, camshafts and all their caps. I installed all of them torqued them to specs installed all new seals seal on specified places, i used engine oil on all bearing surfaces. Last thing i mounted was the high pressure fuel pump on the back of the engine and at this point i'm worried about the engine breaking the mount and falling on the ground. I also need to find or buy a timing belt locking kit, because of adjustable cam sprockets is not as easy as lining up the dots also the crankshaft pully has no key.
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Lo-Fi

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Curious how you change that filter without dumping its contents in the valley??
 

Downunder Bob

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Just about every car, truck, boat, engine or machine has at least one design feature that is of very poor design. Typical is an item that has to be serviced, that is hard to get at. I can recall many that had hard to get injectors, spark plugs. adjusting bolts for belts, chains and pulleys. Drain pugs. There are more but that will do.
 

GoceKU

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Today it was entertaining morning talking to couple of tool companies, i need a timing kit for the engine on my 607 so at first a ask to rent it they wanted like 150$ WTF, then i ask to buy a kit its 400$, so i asked for a picture to see what i'm buying at that price. And i could see cut marks that the tools are home made and the box is generic. So i google the kit number and released they have coped a kit and are selling copies, i did call them back and ask are they genuine, the guy said yes so i started to ask him other questions and he released i'm not buying the kit or his stories, and as a truth salesman comes back you know i can sell it half price if you buy it today. I told him nice try and good luck. But seeing the picture there is not many complicated items in it, main parts are 3 pins so i took measurements of the engine and made me a kit. I used my hand knurling tool, a bit of machining on my lathe and made this, and they fit perfect.
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