206 HDI mod guide (engine stage 3)

In this one I go through my 206 tuning set up and list the mods required for a good jump up in HP and big Torque!

[@boosthit811]

If you enjoyed this video, give it a thumbs up and subscribe. Comment below....

[@flappycheese76]

Could you get a full list of everything that is on it?

[@boosthit811]

ok: EGR delete, HP fuel pump upgrade, Fuel pressure sensor upgrade (1800bar), front mount intercooler, A.C & fan delete, inlet manifold clean out, exhaust manifold ceramic coated, full 3" exhaust with one straight through magnaflow muffler, boost t (set 23psi), crank case breathers to atmosphere, HDI tuners stage 3 tune file.

[@pauliusvilimas3362]

Hey Im going to upgrade my Xsara hdi just like you did. But Im curious from which bmw engine did you take away HP fuel pump? 320d e46 110kw? Or there is not difference

[@schoumv6]

Paulius Vilimas 2.2 hdi and bmw 530d

[@nicolaleone1212]

Please write component codes.. 🙏🏻

[@hipstarchild]

Over the last 3 years, I've invested in a lot of tools and learned how to do pretty much all mechanical work to the little (Reliable) pug. I only wish I knew how to do things like this. This is next level and way beyond me. Nice video !

[@boosthit811]

Thanks for your comment. Was a very reliable car.....the rust just got to it unfortunately.

[@StevenLewis-HDI-Tuning]

Thanks!

[@mm_car_club8651]

Hi I have got a Peugeot 206 hdi 2L can you tell me all the mods and were to find them please

[@kea550]

Hi mate did you replace the fuel pressure regulator sensor with a standard 2.0 hdi or 330d one to match the pump?

[@boosthit811]

The fpr was a new 2.0 hdi one. I believe they use the same Bosh unit.

[@plaxtonexcalibur]

hi, loved the video, im running a 306 with hdi tuning stage 1+ , freeflow exhaust 2.5 straight from turbo, no cat boxes or silencers into 5" semi curved downpipe, fitted huuugggeeeee fmic, egr blank/removed, turbo is super loud, still burns relatively clean, making my way to stage 2 from hdi tuning, just need to get last few bits, shame you didnt keep the 206, i will never sell this, used ecu on previous 306 but not with fmic, with buy another ecu for stage 2, is it worth going down to there workshop for a dyno tune??? and why does it whistle so damn hard and loud, no loss of power...

[@boosthit811]

Haha cool. Thanks for commenting. If you're happy with the drive ability and there isn't loads of smoke I would wait until you do a bigger mod like new bigger turbo or something. Hearing turbo on diesel engine with big open pipe is normal.. 5inch down pipe is massive haha. Just make sure no leaks etc.

[@CarlosGomes-gc5go]

Good friend. I'm making a change in my 206 2.0 HDI to stage 3. But I do not know what kind of sensor from the compatible injection slide or the pump could help me with that?

[@boosthit811]

Hi there, you would need the sensor that I use in the video. But once you change the sensor over you need a re-map to make it work.

[@TsarNateRules]

Did you just have a bog standard Luk clutch and pressure plate with all that torque? How did it handle. My stage 2 hdi slipped like mad on an upgraded button clutch and upgraded pressure plate.

[@boosthit811]

Haha yeah man standard 90£ luk. Skinny 175 biscuit wheels would just light up 1st and 2nd.....they were the weak link on purpose. It would last around 12 month

[@aaronmorrell6280]

Hello, what front mount are you using for the 206 as looking to do mine

[@boosthit811]

It's just a small universal one off of Ebay

[@yimbo1924]

What is the brand and model of the hp pump? Great build 👍

[@boosthit811]

Answer should be down in the comments somewhere.....

[@ej9max]

Hello, i would do the same on a 206 hdi bosch system,do you think i will need the fuel sensor? And switch pins?

[@boosthit811]

Hi, yeah. Exactly the same as in video and you will be good to go.

[@themeanderingmotorhome]

What cutch plate are you using to stop it slipping?

[@boosthit811]

Just a new luk clutch kit. Only last about 2or3k miles. My weak link was the skinny tires....would spin through to 4th in damp conditions.

[@darioalejandrovallejos3455]

hello from Argentina, how many hp and torque do you think you got with all the upgrade? How did the car and engine behave over time? Did you do something to the clutch?

[@boosthit811]

Hey man. Was about 180hp cant remember what the torque was but used standard clutch and they would only last 3000miles if launched/abused a lot. That engine set up was very reliable, had it for about 4/5 years. Main thing was getting it tuned by an experienced tuner. I kept the wheel n tyres small so the were the weak link and helped my clutch and transmission survive. Which worked out well.

[@boosthit811]

I went through 3 standard clutches over the time I owned. About 90£ each clutch kit.

[@schoumv6]

BoostHit stage 3 cerramic clutch and solid flywheel

[@secretmeerkat]

Hey mate do you have a rough price on the parts ?

[@boosthit811]

Probably between 300-500£.

[@nicolaijensen2666]

Hey you, have you any dyno print Outs off the car ? :)

[@boosthit811]

No mate, sorry.

[@slowcheetah53]

That aluminium inlet for intake manifold, is it bolt on or you need to modify it to fit, and from what car did you borrow it?

[@boosthit811]

It's standard mainfold off the car. I just cut it in half to modify it

[@slowcheetah53]

@@boosthit811 no no, i mean this inlet where comes the tube for intercooler, that isnt factory?

[@boosthit811]

@@slowcheetah53 the elbow off of the inlet manifold is a part off another Peugeot I can't remember the model

[@emilrijsemus4178]

What did you use to write the new stage 3 map to ur ecu? what kind of obd ecu reader?

[@boosthit811]

Just used an old laptop with adapter cable

[@sammorrow2618]

Any idea of reliability of the 2.0 HDI engines? Looking at a 306 tomorrow and hoping it’ll be a good daily with some mods thrown at it.

[@boosthit811]

Cant speak for all.....but mine was extremely reliable over 4 years. The main issues are egr valves causing carbon buildup through the inlet tract plus restrictive exhaust system parts like blocked catalytic converters and or dpf"s. Obviously regular oil changes and coolant changes, cambelt replaced at correct intervals.......

[@sammorrow2618]

@@boosthit811 thanks for the reply! Thankfully the 306’s don’t have dpf’s. I’m sure my first mods will be egr and exhaust related anyway so I’ll get that sorted if I do buy it. Cheers!

[@domlambon7662]

Hi mate, I own one of these myself running stage 2 150bhp but my fuel pump is maxed out and I am wanting to do the pump/sensor mod, if you could give us more information about them both and explain more on what you’ve done I would appreciate it massively, cheers!

[@boosthit811]

Alright mate, its been quite a while since I replaced the pump with the slightly bigger one. Your best bet is to send www.hdi-tuning.co.uk/ an email and ask them what high pressure pump to upgrade to. With the sensor it should be the part number that I show in the video. They could also tell you what pins to switch around once new sensor is fitted (they told me) I built that 206 about 5 years ago. Very reliable.

[@schoumv6]

dom lambon cr hp pump from 2.2 hdi

[@schoumv6]

dom lambon or from bmw 530d

[@rasmusandersen1205]

Hi. The new high pressure pump, where did that come from?

[@boosthit811]

Hello, I can not remember the exact model. It was off a BMW i believe. Done that build over 5 years ago.

[@boosthit811]

I think it was the Bosh R70 off of a BMW 530d

[@davidnajarro6227]

Could you explain how you connected the pins un the rail pressure sensor? It could help me so much.

[@boosthit811]

It's been a long time....if I remember correctly there are 3 pins labelled inside 1.2.3. Pins 1 and 2 just need to be switched around with each other.

[@davidnajarro6227]

@@boosthit811 thanks!!

[@anthonycharles8818]

We need some dyno runs 👍👍

[@boosthit811]

Haha. Sold her man.

[@szymonborowski9086]

hey what did you do to the manifold exactly? You cut it off and welded it, can you explain what exactly you did to it?

[@boosthit811]

Just cut it along the centre to get access to all the runners. Then just smoothed everything out. In inside of them is a terrible casting. Almost like mesh. Smoothed everything and blended the entry of plenum to runners, kind of made small bell mouths.

[@antsfur]

@@boosthit811 thats good but how do you join it back together again after you have cut it in half? Thats what I dont undestand, thanks

[@boosthit811]

@@antsfur tig weld it back together.

[@lucardel2745]

Hello bro, just what i got a 2.0HDI 90Hp and i want to start tuning it. Can u help me explain step by step how i can get horsepowers? I live in Romania so its kinda hard to get tuning parts for HDIs

[@boosthit811]

Ebay will become your best place for parts. Just watch my HDI videos and search around KZbin.

[@TechBru22]

How much did the build cost overall?

[@boosthit811]

Probably around 500£ 1000$

[@Nlck_Name]

Thx m8 bought an MPPS and i'll do my remap for stage 1 first off

[@Nlck_Name]

also which intercooler did ya use and how did you block the EGR currently got a 206 2.0l hdi same as yours

[@boosthit811]

@@Nlck_Name just one of those small universal Ebay ones. Bought a blanking plate of Ebay 2👍

[@Nlck_Name]

@@boosthit811 K thx have a good day/night

[@kislenfit968]

Hey mate, what intercooler you buy?

[@boosthit811]

Just a basic one off of eBay. Small universal one.

[@carlosmagnomacieira8210]

Did you change the suspension? I live in Brazil and are roads are terribles... We always have problems with the suspensions of the peugeot cars...

[@boosthit811]

The roads are quite bad here to. No I kept standard....nice and soft. Torsion bar rear so hard to brake.

[@carlosmagnomacieira8210]

@@boosthit811 how much fuel does it consume per km?

[@boosthit811]

@@carlosmagnomacieira8210 use to do 400mile per tank. So that's 12.8 kilometers per litre.

[@carlosmagnomacieira8210]

@@boosthit811 that is almost what ot does stock... That is amazing!!!!

[@TechBru22]

Did you upgrade the brakes or suspension at all?

[@boosthit811]

Brakes are the most powerful thing on her. No kept suspension standard. Great on crapy roads full of potholes.

[@TechBru22]

BoostHit nice! I’ve just bought a 1.1 206 and brakes are terrible even after I did a brake fluid change

[@boosthit811]

@@TechBru22 Geez a 1.1....didn't know they made a 206 that smaller engine! I cant complain about my old 206 brakes just kept discs n pads good plus fluid.

[@antsfur]

@@boosthit811 standard brakes or 180gti 280 something mm or even bigger 305mm ?

[@boosthit811]

@@antsfur was just standard mate. Probably could have done with a pad and or disc upgrade to be fair.

[@nicolaleone1212]

Please help me with my train Xsara 2.0 HDi RHZ 110hp I bought a "new" motor 130'000km and I need to tune it up.. 😅 Please suggest me Parts and Remap I'll like to up it over 190hp (possible?)

[@boosthit811]

Info will be in the comments bud.

[@FrAnbrawl]

Hello ma friend i have the same motor in ma Peugeot 206 xs but i ddnt find anymanual, where i can find a manual :( i only wanna uphrade to stage 1 maybe only change pump, intercooler, deleting EGR? Maybe goods advices u can give me or where u find good manual for 2.0 hdi 90 Greetings ma friend

[@boosthit811]

Manual as in the book? Haynes manuals should make one.

[@antti1325]

Where can i get Gearbox with longer gearing? Almost 3k rpm on 70mph is not so economical🤔

[@boosthit811]

Ha not too sure. Would have to swap the gears. Probably custom job.

[@kurczakpe]

Super .... . Does blanking the EGR require later modification of the engine computer?

[@boosthit811]

Once all mods were completed I then uploaded the new ecu map, that included egr delete

[@kurczakpe]

@@boosthit811 OK thanks . where or from each I can download ECU modifications, ECU modification as I understood is through the OBD connector (sorry, my englisch :) )

[@boosthit811]

@@kurczakpe yes that's correct. Using laptop connected through obd port. HDI tuning

[@boosthit811]

@@kurczakpe hdi-tuning.co.uk is who I used

[@kurczakpe]

@@boosthit811 Ok

[@williamvesterberg1107]

Would this work for the 207 sw 1.6 hdi?

[@boosthit811]

They are a different layout but the same principles apply to all engines. The more cool air they can pump the more power potential.

[@richbrown5852]

The 1.6 HDi maps up better truth be told, especially if you're going to stage three, there's a pdf walkthrough on HDi tuning website where it sits about 200bhp and a buttload of torque. Very much tempted to do the mods to the Mrs 1.6 HDi/tdci!!

[@malcolmsaysomethinggreatka2017]

@Rich Brown, why the hell not mate. 😁 hell yeah!

[@New777Wine]

Very cool. Do you have any experience of running veg oil in the 2.0HDI?

[@boosthit811]

Thanks for the sub! No I haven't used veg oil before. Only cooking chips.

[@Fuckingenius]

modern diesels dont like veg oil. it can clog all the fuel system too by becoming jelly. personal experience with an old fiat uno 1.3D

[@boosthit811]

@@Fuckingenius Exactly 👍

[@malcolmsaysomethinggreatka2017]

Veg oil, definitely a no, no. Period. In tank pumps barely last two years before packing up. Just crazy.

[@fanattyzm8137]

Automatic trans will handle this mods?

[@boosthit811]

Not too sure on that.....

[@PRTXgamers]

I have a 1.6 hdi DV6 (8v head) on the new 208. Lest see if will work that.

[@boosthit811]

.......interesting 👀👀

[@PRTXgamers]

@@boosthit811 its the 92bhp. I put the k&n air box filter, and the car feels much fast to respond. Next step is DPF off, EGR off, remap.

[@boosthit811]

Nice 1. Yeah the older factory exhausts can be quite restrictive. There much more fun to drive once remap complete.

[@boka2125]

What intercooler inlet and outlet diameter should I use?

[@boosthit811]

2 1/4" should be plenty

[@boka2125]

@@boosthit811 thank you for answering quickly. Found one universal intercooler with in/out diameter of 53mm. That should be fine?

[@boosthit811]

@@boka2125 yeah that will be fine for a little 2.0hdi

[@swap_g_box6971]

What power does be4 withstand on slicks with a good grip or do you need a swap of another gearbox for high power? maybe from 407 2.2? I am building a high-performance turbo engine and I am interested in the tensile strength of the stock transmission and clutch

[@boosthit811]

Hello, I kept the standard tyres/wheels for that reason. So the week link was the traction of the tyre rather than gearbox. Also less stress on clutch. All that said I don't know of anyone braking the transmission, but as with everything I'm sure theres a limit.

[@swap_g_box6971]

@@boosthit811 What's your current gearbox and clutch on your 206?

[@boosthit811]

@@swap_g_box6971 standard gearbox and standard clutch. The standard clutch would last about 12 month....

[@antsfur]

@@boosthit811 lol ! My clutch is 18 years old still original in my 206 2.0L hdi i guess that would last an hour or less !

[@boosthit811]

@@antsfur haha.....it would definitely test its limits

[@alanchatfield4271]

350d or 530d

[@nickjames6013]

What pulley did you run on fuel pump?

[@boosthit811]

The same standard pully.

[@nickjames6013]

BoostHit from the Peugeot?

[@boosthit811]

@@nickjames6013 yes, carefully undo the hp pump pully nut that's on the cam belt. Remove pump carefully without bumping cambelt timing...then slide new pump into location and loctite nut. All those bosh fuel systems seem to use same hard parts. The hp pump doesn't need timed up.

[@nickjames6013]

BoostHit thanks good to know. I have a bit of mad set up the ecu and loom is from Peugeot 206 hdi but the motor is from a Vw golf mk3 1z 1.9 tdi. It was a motor from an old build had all ready upgraded some of the internals

[@boosthit811]

@@nickjames6013 that does sound mad ha. She running?

[@carwyncurrado3565]

Would this work on a 2002 306 2.0 hdi 90 estate

[@boosthit811]

Pretty much. Does it run a Bosh fuel system?

[@carwyncurrado3565]

Not to sure only bought the car Sunday...need clutch as bearing is noisy...after that I want some more power and some black smoke hahaha

[@carwyncurrado3565]

@@boosthit811 have you got a contact number if I get stuck?

[@boosthit811]

@@carwyncurrado3565 d.m me on Instagram.

[@carwyncurrado3565]

@Boosthit I don't have Instagram

[@Chris-rf8nj]

Why do i need to switch pin 1 to pin 2 ?

[@boosthit811]

To run the new fuel pressure sensor

[@Chris-rf8nj]

Do you think the 55PP02-02 MY A Will be ok too?

[@BMH1965]

Removing the EGR valve makes the car illegal.

[@ayyyyyy]

Is he really going to be pulled over for not having an EGR though? worst case scenario is to put it back on for MOT but that's it.

[@lukecowell7516]

Mot Cant even seen its been removed

[@NoFearGeorgeCz]

Hi, do you have instagram that I could contact you on? Thanks🤟🏻

[@boosthit811]

Yeah go onto my channel and then you should see in the description....

[@jordan28803]

Stage3 on a standard turbo 😂

[@boosthit811]

Yeah man, bogin deep, she took it like a champ.

[@een-stoom-liefhebber]

What turbo would be better than stock? I still have the engine from my crushed 206 sadly it is the 1.4hdi i'm thinking about to fully rebuild it in the winter and buy a sheap 206 with engine trouble, only the fuel pomp from bmw sounds crazy what model will do?

[@jordan28803]

@@een-stoom-liefhebber sonthing along the lines of a Gt2052v ;) or its Gtb equivalent.

[@sandermaas9734]

Can I bring my car to you I want the same specs. Let me No sir

[@boosthit811]

Could do something in January

[@sandermaas9734]

@@boosthit811 do you have insta