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A sub project that should never of been a project- DCi65



  Ph1 172 & Clio DCi
So I decided some time ago that I needed some cheap motoring in my life and where better to turn than a Clio DCI, £30 a year tax, big MPG, it just had to be a winner.

I struck lucky as a girl I use to go to school with called and said she had seen i did alot with Clio and would I be interested in her Clio that had blown the engine up as the turbo had gone!

Now this being my life, nothing was easy! She said she wanted £150 for it and I could have it. I drove 3miles from my house to hers to pay the cash and collect the car with a mate and a row rope.

When I got there she told me the car had blown up in Essex at her work and it was sitting in a greyhound training farm with the paperwork in the glovebox and the key under the sun visor!

No biggy, me and 2 mates jumped in the tow car and drove all the way to Essex to be greeted with a fully locked and closed training facility. After a short phone call to her she insisted we could just jump over the fence and unlock the gate from the inside and that's what we did.

In the corner of the yard, there she was. My new purchase! As we started to rig the DCi up to the tow car (it was pretty dark by now) we were greeted by a rather unimpressed guard dog that wasn't very happy to see us!

I managed to drive the DCi out the yard and down the road a bit on the starter motor as my mate jumped in the tow car and shot off down the road! We jogged back, shut the gate with the dog locked in the yard, Jobs a gooden :)!

We towed the DCi threw central London from Essex all the way to Staines on a rope!! 70 odd miles. The amount of people who tried to get between the tow car and the DCi in London traffic to be greeted by a tow rope was hilarious.

After a safe return back to the workshop, the work begun, old engine out, complete new engine in. Start it up and it sounded like an utter dog! 4 totally dead injectors! £600 in Renault later and she was alive, be it bloody slow!

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When your use to a 200bhp Ph1 172 as a daily, this really doesn't excite you in anyway shape or form. How ever, 600ish miles to a tank and £30 a year to tax, who really cares. I PROMISED myself this was a cheap get around and all spare funds would be going towards my Westfield Cosworth project AND THE DCI WOULD REMAIN TOTALLY STANDARD!

How ever. Lately I've sorta slipped up, it all started with a cheeky remap, i mean what the hell, I own the kit to do it so why not. The gains were epic! It turned quite a mundane boring to drive car into a little warrior. Loads and loads of torque. It just made it feel right and when you went to overtake someone at 70mph, it just felt more safe to do so!

Next I went over the local scrapyard for a wiring loom from a mini for the westfield only to be greeted by a DCi106 that had been smashed hard up the back! It had always bothered me that my DCi didn't come with an intercooler and as there was one here with all the pipes for £40. Baaahhhhh what the hell!

As I had all the boost piles off my DCi anyway to fit the intercooler I decided to remove the EGR valve too as if I drove round town a bit, the next time I gave it a boot full, it would smoke the town out, then clear so I decided to rule it out anyway.

Removing the EGR valve and housing perfectly exposed the actuator arm for the turbo and I noticed it was adjustable from the factory! As it was now intercooled I though what the hell, a bit more boost won't hurt and wound it up by quite a margin.

THE RESULTS ARE EPIC!

Thanks to the lack of EGR and colder air the fuel consumption has got even better than it was! And the little 1.5 has been turned into a little powerhouse. The car is So So So much fun to drive now. It really takes off well from as little as 1500rpm in any gear whatso ever.

I'm really really happy with it, so happy infact, I've just agreed to buy some Turinis for it. :)
 
  Cup In bits
Some cars just lend themselves to cheap motoring and modding, can't beat it. 306 is another and Escort van or any 90's diesel ford really.
 
  Ph1 172 & Clio DCi
Have done a little more to the old girl today!

She clicked over to 164000miles so I gave her a fresh sump of oil and a new filter. I like to change the oil on my own cars every 6-8k.

I also ordered some gloss black vinyl to fill in the rear windows to make it look like a van. More often than not, its used as a van anyway. £9 delivered off eBay and I didn't hold much hope but it actually looks really good (I think)

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Next after changing the springs on my brothers turbo clio too coil overs, I nabbed his old apex springs off him to fit to the DCi car/van. The springs are firm but I think the ride hight is spot on.

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Tomorrow I collect my new wheels from the refurb'ers. :)
 
Really like this project. I've got a dci 65 myself. I don't use it. Havnt for months but it cost me 700 and I'm refusing to sell it

Probably by a few bits when I start using it again
 

Dr HMS Derv Destroyer

ClioSport Club Member
  MK1DTi/vivaro/corsa
what boost you running at now? :)

also the egr delete, did you do it the way everyone does and blanks the collector pipe and bridge the boost pipes or weld the manifold hole and connect the pipes together?
 
  Ph1 172 & Clio DCi
Not sure exactly what boost its seeing now but WOT in 4th and 5th tiggers the boost cut so I need to turn it down slightly.

I totally removed the EGR housing and blocked the pipe off that came from the exhaust manifold. Then just linked the pipes up!

The turbos a smoky old turd anyway so I'm in talks with the turbo people I use about giving them my DCi65 turbo and them giving me a Hybrid DCi80 turbo.

I've got the bug for it now! I may even get it on the rollers tomorrow and see what it's making as it pulls 5th gear now how it pulled 3rd as a standard car.
 
  Ph1 172 & Clio DCi
FLOL! Cheap run around, suddenly one thing leads to another.

Glad you're enjoying shed motoring.

The funny thing is, it's still cheap!

I took it to Birmingham yesterday evening. Did 240 motorway miles and 60 round town miles. 40 of the town miles and 120 of the motorway miles we had 2 people, 4 15inch alloy wheels and an engine complete with ancillaries. A d it averaged 60mpg!
 

Dr HMS Derv Destroyer

ClioSport Club Member
  MK1DTi/vivaro/corsa
ah right, keep an eye on the pipe , some of us have had them blow off with pressure from blocking.
have you found a way of mappin out the egr all together, i still have mine plugged in to stop the dash lights :(

haha , love the boost over warning, had that to much and it killed one of my old engines. trueth be told i spun the actuator open to near enough full.
boost safty kicks in at around 1.5 bar

how much you looking for a hybrid turbo 65 to 80 remake? theres brand new dci 80 turbo's
k35's on the bay for 195 delivered. got one when the turbo went first time around.

was descussing to james in another thread that i'll have to pop down and get my dci 80 properly mapped after sorting out all my engine issues.

great little cars, and the added bonus you've done te injectors, so no worries for another 90K+ miles hopefully.
fuel pump might need changing in the future. best to catch them early before it destroys the whole fuel system.
 
  Ph1 172 & Clio DCi
I left mine unplugged and so far I've done 1500miles with no light or limp mode.

Apparently there's a trick I read on www.cliodci.net with a resistor that works but it hasn't been an issue for me. 1.5 bar sounds about right. You can hear the turbo really going for it.

The hybrids will be around £350-£400. He won't know till he's done mine. But that's absolute worst case money.
 
  Ph1 172 & Clio DCi
What engine issues are you having.

If the EGR is left plugged in the ECU will still add extra diesel to compensate for it working? And if its not actually there then that can cause issues.
 

Dr HMS Derv Destroyer

ClioSport Club Member
  MK1DTi/vivaro/corsa
i dont exactly know what the egr tels the ecu, other than it supposedly making the car more eviro friendly by letting amounts of gases back in until WOT which it shuts off the exhaust gas bit. they are usless tbh, known so many people complain from bad idle and lag serge from stand stils.

i have mine all deleted but the soliniod still plugged in , due to the lights and the resistor trick wont work.
tested with and without on a MOT machine, makes no difference. neither does a decat TBF

get a decat made up, you'll love it! turbo spools up so much easier and then noise is nice. ;)

engine issues... suprised you havent heard of the troubled dci on here. its had 2 engines. and im now going onto my 3rd.

1st one ( original ) was fucked from a timing issue,which took the oil pump with it.
2nd one died of bottom end failure , bent 2 rods and badly dammaged the crank enough to be out of fixing limits.
same engine wouldnt accept new injectors, and the fuel pump went on that aswell.

3rd one is sweet and nice low millage, new injectors and pump. tappets all reset aswell.
hence me getting it mapped soon ,as i had it mapped before ( which i blame for the bottom end failed ) and it was fun to drive. standard feels sluggish



not allot goes wrong on them. only fuel pumps and injectors tend to go funny.

everyone knows the egr can lead to premiture turbo failure so deleting it helped allot.
all you need to know is pritty much on cliodci.net which you know already.

as they say, a mechanics car is well looked after :eek:
 
  clio 172 phase 2
Haha love threads like this ! Cheap dervs are full of win ! I had 306 d turbo turned the boost and the pump up went like a stabbed rat she was a smokey old bus though :/
 

Dr HMS Derv Destroyer

ClioSport Club Member
  MK1DTi/vivaro/corsa
insurance group 4 from memory. idk that the 1.2 is lower but bang for buck, dci's are the best option ( in clio's for young people )
 

Knuckles

ClioSport Admin
And tyre shine :eek:

genuine lols were had at the op... At blatantly stealing a car from a locked car park and people trying to pull in between it and the tow car :p

this is making me want a DCi as a daily lol! The £30 a week I use would probably last a month haha
 

aucky

ClioSport Club Member
I think the tyres would benefit from a good scrub with APC before re-applying tyre shine. They still look a bit grey (or is it jus tthe photo?)
 
  Ph1 172 & Clio DCi
Couple of bits a bobs done to the car this week.

Gen Renault Clutch kit
Gen Renault High pressure pump
Gen Renault Cambelt, auxbelt kits coolant and water pump
Michael Woodford Motorsport spec hybrid turbo.
All new track rods, track rod ends and ball joints.
Home made de-cat.

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  182/RS2/ Turbo/Mk1
Looking forward to having another go in this now its got the hybrid on it.

Bring it tomorrow night so I can drive it home from TKD!
 
  clio 172 cup
not alot really i did the same minus the new turbo he got,
i got a doner for 650 failed mot on steering play rust on sills 2 bald tyres took of the front end rear bumper interior ect sold the engine and box for 250 scrapped the rest for 130 so only cost me around 250ish
 
  182/RS2/ Turbo/Mk1
not alot really i did the same minus the new turbo he got,
i got a doner for 650 failed mot on steering play rust on sills 2 bald tyres took of the front end rear bumper interior ect sold the engine and box for 250 scrapped the rest for 130 so only cost me around 250ish

Would cost you a LOT more than that to do what Mike has in terms of the new genuine high pressure pump etc, thats more than your entire budget gone in one go, lol.

I would say this lot:
Gen Renault Clutch kit
Gen Renault High pressure pump
Gen Renault Cambelt, auxbelt kits coolant and water pump
Michael Woodford Motorsport spec hybrid turbo.
All new track rods, track rod ends and ball joints.
Home made de-cat.


Is over a grand in parts?
 

Dr HMS Derv Destroyer

ClioSport Club Member
  MK1DTi/vivaro/corsa
would love to see if you can break the 130hp barrier without the pump retarding mike :)

how come the new pump? thoughtyour old one was suf enough
 
  Ph1 172 & Clio DCi
would love to see if you can break the 130hp barrier without the pump retarding mike :)

how come the new pump? thoughtyour old one was suf enough

Old pump had done 167,500 miles and very occasionally under high load the engine management light would briefly come on with the code Low Rail Pressure. As I was doing the cambelt anyway I thought I might as well put a pump on, as if it did finally give up the goast, I didn't want it to swarf up my brand new Gen Renault Injectors.

Feels good to drive now. New turbo has to boost set much lower so I need to get the mapping stuff out and raise the boost again.
 
  Ph1 172 & Clio DCi
Would cost you a LOT more than that to do what Mike has in terms of the new genuine high pressure pump etc, thats more than your entire budget gone in one go, lol.

I would say this lot:
Gen Renault Clutch kit
Gen Renault High pressure pump
Gen Renault Cambelt, auxbelt kits coolant and water pump
Michael Woodford Motorsport spec hybrid turbo.
All new track rods, track rod ends and ball joints.
Home made de-cat.


Is over a grand in parts?

Yeah man. That lot was just over a grand.
 

Dr HMS Derv Destroyer

ClioSport Club Member
  MK1DTi/vivaro/corsa
Yeah better to be safe than sorry.
Tbh as long as you don't run the tank to the red the fuel pump will last 100k miles ect.

Need to see the turn out of this! :)

Btw have you smashed the cats internals out?
If you have, fab a proper 3inch pipe up to replace it. Found out I was losing 10-14 torques from the hollow VOid
 


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