Peugeot 305 TD Conversion - Petrol Engine Removal

Part one of the turbo diesel conversion on my 1986 Peugeot 305 GTX.
This car had the 1.9 XU 8v petrol engine fitted with a Webber 32-34 DRTC carburettor. It is a similar engine to what the 205 GTI would have got, at least the block is, camshafts may differ and of course it did not have fuel injection. The engine never run terribly well, quirks of having an old carburettor and distributor is it was in need of a good tune. I could find no one to tune the carburettor that might have improved it but the iffy running meant that i never really used this car a great deal. The plan is to fit a 1.9 Turbo Diesel XUD9TE removed from a 1993 Peugeot 405 estate, featured in a video i did years ago on this channel. That engine has been fully rebuilt and actually sat for about 2 years in this shed, other projects and life got in the way but finally the 305 is getting the engine it should have always got.
This is the first video in the process, i will try and do a few update videos covering the bits of work required for this conversion. This being my own car i am inclinded to spend a bit more time and effort on the conversion than the recent 205 TD conversion where the owner just wanted it finished as quickly as possible. Therefore the 305 will be getting a front mounted intercooler, the car will also be getting a hydraulic clutch conversion, initially converting the 405 pull type clutch to hydraulic actuation but in the future having a hydraulic clutch lends itself towards accepting a later HDi gearbox for better ratios.
Any suggestions (apart from keeping it original... too late for that now ;) ) as to what to do with this conversion are welcome.
Tools Used:
1/4" Socket Set: amzn.to/37hvQzh
3/8" Socket Set: amzn.to/2Q312wu
3/8” Long Ratchet: amzn.to/3f4gbYG
1/2" Socket Set: amzn.to/37jBAZy
1/2” Impact Socket Set: amzn.to/2yPxufM
1/2" Breaker Bar: amzn.to/39kBSRB
Screwdriver Set: amzn.to/2MAGgly
Torx Screwdriver Set: amzn.to/2u1zE9B
Pliers Set: amzn.to/2QtGYT2
Sump Plug Sockets: amzn.to/36a0D0Q
Impact Wrench: amzn.to/358hBeC
Transmission Jack: amzn.to/2sx4g2a
Axle Stands: amzn.to/3aW3L2R
Knipex Side Cutters: amzn.to/2Ry4H5L
Ratchet Spanner Set: amzn.to/3cpdIpI
Oil Drain Tank: amzn.to/2t9nKtO
Exhaust Hanger Pliers: amzn.to/2A2PmV5
Equipment used to make video:
GoPro: amzn.to/2SBe9H4
Main Camera: amzn.to/2skwuxl
SD Card: amzn.to/39m2xNM
Computer: amzn.to/39lIXl2
Follow the peugeotcitroen2cv Facebook page: / peugeotcitroen2cv

[@MrBenjaminTea]

I could never get the 32/34 DRTC to behave on my 305 GTX - I eventually replaced it with a Weber DGV which was better but a bit jittery, which Mr HubNut pointed out when road testing it. Had I kept it, I would have been doing this exact conversion! Instead I'm putting an XD3T in my 505 estate.

[@peugeotCitroen2CV]

I have a 305 automatic on the same carb, its a bit better presumably the auto box takes up some of the jitters, although the first start in a while it can splutter and act up until it gets warm, the auto choke being partially to blame. I have an EFI engine from a 205 1.6 for that particular 305 might make it a bit easier to run, although the XUD was hard to beat. XD3T sounds like a good engine in the 505, what does it have currently? Is that the same 505 estate that Ian reviewed?

[@tarekdiab100]

Love it

[@FrankypankyV8]

You're crazy... But my kind of crazy, haha! Never dream of building a kitcar? Greetings from the Netherlands!

[@peugeotCitroen2CV]

Haha thanks, better to be thought of as crazy than boring. A kit car, it would be an appealing proposition the way caterham can supply you with the car in a box to assemble would be good fun, although its still new car money. Its not quite a kit car but i do have an MX5 lingering in the shed, never really got them till my dad bought one then didnt want it because he was too tall. I bought it off him and i totally understand why they are so popular an absolute hoot to drive even with a 1.6 and no Limited slip diff. At some stage i would like to modify it a bit.

[@NikolaPASULJ]

Oh gosh, a GTX converted with a diesel engine 😱 ultimate sacrilege 😅 6:20 nice 405 seat 🥰 The exhaust looks new, did you buy recently

[@peugeotCitroen2CV]

Haha yes it might upset some purists but it was not a particularly pleasant car to use with this petrol engine, having done a 205 with a turbo XUD they really are a handy engine to get a good level of power yet also economy, living in northern Ireland if i wanted to drive over to pug fest this will be able to do it, plus most 305s people remember were diesels. That 405 seat came out of the same car the donor engine did, I've also got a 406 seat doing the same job, handy when the lift doesn't go to the full height it would be sore on the knees trying to stand under the car. This 305 sat in a shed for most of its life, so it is quite solid including the exhaust. Only downside were the mice nests and dust but thankfully it cleaned up.

[@NikolaPASULJ]

peugeotCitroen2CV : mine engine GTX have no confort problem, he’s pleasant. Sometimes, carburetor must be tune for a functionnaly engine. The cold idle at 2000rpm is not normal. But, Solex carburetor is easy to tune for best drive agrement. However, the XUD9TE is a very good engine ! Strong, economical and powerfull as necessary . A part that love in all my 405 is the confort of seat, particulary the SR finition 🥰 Lovelly !

[@philippepetit3105]

I DID THAT JOB ALREADY IN THE NINETYS I THINK IT WAS THE BEST CAR I EVER HAD

[@philippepetit3105]

IT TOKES ME 3 DAYS TO DO THE CONVERSION INCLUDING THE ELECTRICAL SYSTEM YOU HAVE TO TAKE CARE CAUSE SOME PINS ARE NOT IN THE SAME PLACE IN THE MAIN PLUG

[@peugeotCitroen2CV]

@@philippepetit3105 Im still dithering about with this project, its getitng a front mount and hydraulic clutch which took a bit of fabrication. Then other cars have come and went needing work pushing this back

[@philippepetit3105]

@@peugeotCitroen2CV YOU'D BETTER USE THE ORIGINAL GEAR BOX WITCH FIT WELL ON THE xud 8

[@peugeotCitroen2CV]

@@philippepetit3105 Can i just ask, why the CAPS LOCK it seems like you are yelling? With regards gearbox i tried the gearbox on the 405 TD but am adament that this car will have a hydraulic clutch. That has led me down the route of getting a 406 HDi 90 flywheel, clutch kit and gearbox so i can avail of its hydraulic clutch, the gear ratio in 5th will also quieten it down a bit on the motorway.

[@philippepetit3105]

@@peugeotCitroen2CV no the caps lock is cause i play a game with

[@aldira2012]

you must change radiator to an over big, and put too two ventilo in your place, i look for an intercooler like the 306 td because there is no place before the engine for an intercooler frontal mine is GR estate 1986 and now GRDT estate after changing engine for an xud9te of 306

[@peugeotCitroen2CV]

Ive got a big cooling radiator sitting in it for when i get back round to doing it Intercooler though i have a front mount one there but its a bit of hassle on the 305 becuase any front mount manifolds i have got hold of foul the brake servo on right hand drive 305's So i need to try and use a 406 arrangement to put the servo on the passenger side to clear the manifold or just use a top mount intercooler like the 306 and 405 used. I still have the original top mount intercooler from the 405. Just the project has been pushed to the side, i tend to need the lift for more pressing bits of work. Something i hope to get back to when i build a new shed in the next couple of years.

[@tinatpasselepoivre]

I envy you brits to have permissive laws on engine swaps... Here in France it's a solid '' no and never going to be legal '' Oh and don't the stock rad looks a bit small for a TD?

[@peugeotCitroen2CV]

You do need to inform the DVLA and it will have to be declared as a modification for the insurance company. With regards the radiator the petrol one is far too small, the core for a TD is around 52mm, one choice is a 205 TD radiator which costs about £230. There might also be the option of getting a big aluminium radiator for something like a nissan 200ZX which costs £130 and make it fit. It's all things that have to be figured out along the way.

[@volvo480]

You can export the car to a country with more loose regulations and after approval import it back into France. EU law stipulates that a car allowed in one EU country must be accepted in any other. This way you can get kit cars approved by applying for a Single Vehicle Approval in the UK and then import the car in your own country. Unfortunately, Brexit will end this U-turn construction.

[@user-bj4ol2wp2o]

عربيات جميله جدا ياريت يتم تصنيعها مره اخرى

[@volvo480]

There is a Dutch guy who took this conversion a step further and put a 406 2.0 HDi engine with 306 gearbox in. The approval by the authorities wasn't a real issue. Nevertheless in our country any diesel powered car prior to 2005 is hit by a tax hike and banned from driving in more and more cities. In Belgium, France and Germany same story.

[@peugeotCitroen2CV]

I remember seeing that video a really good job where he even had the central locking functioning with the flashing lights I had considered a 2.0 HDi (one of the all time great PSA engines) but went down the XUD route for convenience, this particular engine i spent a silly amount perhaps unnecessarily having fully rebuilt. With regards tax i am not sure how this will work, over here diesels are not too bad yet, this will be kept fully legal and reregistered with its engine swap. Whatever the road tax will be so be it, it will not be a daily driver just a car for the odd long cross country road trip in the summer months.

[@volvo480]

@@peugeotCitroen2CV diesels already had to pay three times the tax of a petrol-engined car (diesel fuel is a lot cheaper than petrol though), based on which 100kg weight bracket the car is in and now there is a 15% tax hike if the car doesn't have a DPF, expect to pay € 1600 (over £ 1400) a year for your car. So there is no point here to keep an old diesel car unless you are making a lot of highway miles or SORN the car until it is 40 years old (then it will be considered a classic car and exempted from tax). I do have very fond memories of my 2002 Peugeot 206 XS 2.0 HDi which I drove from new till 2005, it kept on pulling even on the steepest motorway inclines! The old PSA diesel engines are virtually indestructible, there are cars with the clock stuck at 999,999 kms because it doesn't count beyond a million. Everybody seems to loathe French cars but I love the engines and the ride.

[@peugeotCitroen2CV]

@@volvo480 We are not too bad here for vehicle tax, living here in Northern Ireland the taxing is done through the UK's DVLA but i know that in the republic of ireland the tax is very expensive as the car ages. Anything nice at all diesel or petrol. With so many HDI cars still in a reasonable tax bracket the still keep on running here, definitely the old 2.0 HDI can cover some astonishing mileages without any issues. I really don't get the loathing for french cars, they have niggles like electric window mechanisms, airbag lights etc. Ive made videos showing how simple these are to fix yet still get ignorant comments criticising the french engineering, in my opinion their cars last very well.

[@WorivpuqloDMogh]

I have a 1997 Xantia 1.9SD. Apparently in Wallonia they will ban any car from before euro 4 from 2025. They recieved a significant amount of backlash. Not to mention half the population in Wallonia drives older cars. But the government doesn't seem to care. Belgium is basically split in 2 the 2 halves each have different rules

[@Bustrainluvr2k24]

Can you sell the old petrol engine

[@peugeotCitroen2CV]

Trying to at the moment, its listed on the 205 owners club have a few people making enquiries. Only issue is im in northern ireland so shipping costs must be considered.

[@NikolaPASULJ]

@peugeotCitroen2CV : i’m near Roscoff in France. If you come with ferry for holidays, came with engine of possible 😉

[@BITTYBOY121]

Had this same engine in a 1985 Citroen BX 19 GT I once had and It was a complete nightmare, It kept missing/sputtering/cutting out due to a bad/blocked carb :(

[@peugeotCitroen2CV]

Ah the old carbs were just a temperamental nuisance, fuel injection or the diesels really made a huge difference to these.

[@BITTYBOY121]

@@peugeotCitroen2CV Agree 100% 👍

[@riadhkrys7777]

nice job ! how can i contact you ?

[@peugeotCitroen2CV]

Why do you ask?

[@riadhkrys7777]

@@peugeotCitroen2CV i have some questions about my 305

[@peugeotCitroen2CV]

@@riadhkrys7777 unfortunately the Peugeotcitroen2cv Facebook page is down waiting for that to come back. However there is also Peugeot 305 Saloon, Estate & Van UK & Ireland Owners Facebook group mention in the joining questions you sent me a message on here.

[@riadhkrys7777]

@@peugeotCitroen2CV i will check it thank you