Nothing exciting here, just a small write up of my intercooler project.
I drive a 306 HDi (3 door) which comes with a 90bhp 2litre diesel engine as standard, the Citroen Xsara shares the same size engine but was intercooled as standard producing 110bhp! something Peugeot never offered
So, in quest for greater efficiency and more power, I bit the bullet and decided to intercool.
Three guys (and a few others who I can't remember) over at the TDCi forum have all used this intercooler, and its turned out great.
Once you've intercooled the car.. you can remap to 155bhp with 260 ft/lb of torque. An uprated clutch is required but its all fun
Anyhow, enough of the boring stuff. Heres some pics from last weekend.
Mounted.
Chop,Chop,Chop,Hammer..File..,Chop,Swear,Chop,File,Hammer.. that'll do.
MMm..Black silicone :mrgreen:
Top bend with original 406 HDi silicone/rubber hose, bodged together for now. Eventually will be replaced with custom stainless to the top inlet bend.
Original bottom 406 HDi boost pipe from turbo, I had to cut this down a bit as it was far too long! , Unfortunately whilst holding the plastic pipe in the pipe vice.. and trying to push a stuborn silicone bend on I came acropper! , the pipe slipped out of the vice.. I went flying forward and smashed my thumb taking a big chunk out it and splitting my nail damn near in half. This is why it took me sooooo long to put everything back together! [-X
Not the best welding in the world.. but I've not heard it leaking, to be fair though.. I had 1.00mm Mig wire and I was welding 1.5mm stainless! 1.00mm wire is far too big for thin stuff, I got off lightly.
I've already flashed the ecu to 120-125bhp. Since intercooling the car is a lot nicer to drive.
I'll be fitting the new clutch in a few weeks. Then getting a second remap to 155, I've still not decided if I should run it at the RR...
**update**
Bumper back on, literally only just took the picture. Not the best
I drive a 306 HDi (3 door) which comes with a 90bhp 2litre diesel engine as standard, the Citroen Xsara shares the same size engine but was intercooled as standard producing 110bhp! something Peugeot never offered
So, in quest for greater efficiency and more power, I bit the bullet and decided to intercool.
Three guys (and a few others who I can't remember) over at the TDCi forum have all used this intercooler, and its turned out great.
Once you've intercooled the car.. you can remap to 155bhp with 260 ft/lb of torque. An uprated clutch is required but its all fun
Anyhow, enough of the boring stuff. Heres some pics from last weekend.
Mounted.
Chop,Chop,Chop,Hammer..File..,Chop,Swear,Chop,File,Hammer.. that'll do.
MMm..Black silicone :mrgreen:
Top bend with original 406 HDi silicone/rubber hose, bodged together for now. Eventually will be replaced with custom stainless to the top inlet bend.
Original bottom 406 HDi boost pipe from turbo, I had to cut this down a bit as it was far too long! , Unfortunately whilst holding the plastic pipe in the pipe vice.. and trying to push a stuborn silicone bend on I came acropper! , the pipe slipped out of the vice.. I went flying forward and smashed my thumb taking a big chunk out it and splitting my nail damn near in half. This is why it took me sooooo long to put everything back together! [-X
Not the best welding in the world.. but I've not heard it leaking, to be fair though.. I had 1.00mm Mig wire and I was welding 1.5mm stainless! 1.00mm wire is far too big for thin stuff, I got off lightly.
I've already flashed the ecu to 120-125bhp. Since intercooling the car is a lot nicer to drive.
I'll be fitting the new clutch in a few weeks. Then getting a second remap to 155, I've still not decided if I should run it at the RR...
**update**
Bumper back on, literally only just took the picture. Not the best
Last edited:
nice one
Mr Whippy though... he sold his 
