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Hi All, I have an opportunity to get a low miles (45k) XD3T engine that is sitting on ice an hour away from me. I'm planning to drop it in my 1982 Peugeot 604 BA10/5. Before I do that, I've been exploring some tuning that I could possibly do. Here's kind of my general plan: 1. Get an Exhaust gas Temp sensor and Boost Gauge 2. Find an XD2 (non turbo) Intake Manifold 3. Cut and weld shut the Exhaust Gas Recirculator valve opening on the exhaust manifold 4. Add a intercooler and route it from the turbo to the XD2 intake (better clearances than XD2S which has like 2 inches of room between it and the intake) 5. Turn up boost with boost controller from 8 psi to 12-15 psi 6. Turn up fuel on injector pump (easy as turning a screw) 7. ???? 8. 150 HP easy! I don't know if I will be able to shoe-horn an intercooler in there with the A/C and everything, but if I swap in a different air filter assembly I'm hoping that would free up enough space to run intake hosing by. This may just not be possible tho. I'm curious how the XD3TE's fit an intercooler in - that may be the way to go too! XD2s manifolds would just be easier to find in the US. Would love to hear people's thoughts!

Hi All The IP on my XD3T is leaking at the body halves seam. Can you recommend a reseller or rebuild? (8v of fury?) Can anyone share the sequence and details of the IP R&R procedure, steps, torque settings etc? Is there a vendor who sells XD3T workshop manuals (Haynes?) Or. Is there an online resource for manuals in pdf? Thanks.......JoE

I was contacted by a gentleman in Boston looking to find homes for two 1986 505 Wagons. One is a very rare XD3T TD 4sp auto wagon, the other is likely just an XN6 gas wagon: ----------------------------------- I drove the 86 for a while and liked it. I picked it up from a couple in Cambridge. I had Frank Bowman (Peugeot mechanic in New Bedford) check it out and he told me that the oil cooler was leaking bad. He disconnected it said that I could drive it without an oil cooler. I did but thought that the oil ran hot. I don't remember why I stopped driving it. The 4 speed was nice and when I bought the car was told that it had recently been rebuilt. As I recall the car has about 225 miles on it but I am going from memory and could be wrong. It was a second car and more a toy. The 86 definitely would need to be towed. Rust on the surface is not too bad. Don't know about underneath. The TD is missing the fan assembly and radiator as well as the front power window motors. Otherwise it is mostly complete. The injection pump is off the car but I have it. It has the leather interior that is in good shape. I also have an 86 gas wagon that is in the same situation, has not run in 15 years but did run before that. The only real problem was the starter circuit was weak. Contact owner: joseph lenihan - j3star (at)outlook.com

As discussed in my 505 TD wagon build thread, I had played around with various ideas to extract more performance from the 2.5L XD3T engine, and after reading the VWdiesel.net forums I decided the AAZ hybrid injection pump and 2-stage injector idea needed to get pursued. (I blame Automotive ADD). I contacted a one of the users on VWdiesel.net as I noticed he was in Saskatchewan and we chatted via e-mail for a bit. (Great guy.) A few weeks later he sent me a link to a post selling some used XD3T pumps on the IDI forums. After some negotiation - I bought one of the pumps he had for sale. (Condition was unknown since it was off a car in a pick and pull yard.) The seller of those pumps told me about the special registration process for the site - so I joined after finally getting my request approved. With a core XD3T pump found, the first task was to put an advert up for AAZ injection pumps as well as some AAZ 2 stage injectors. Now that I was on the forums I could actually contact people, and make more inquiries. After reading about the governor mod the VW guys do, I noticed the author of the article (8V-of-fury) was also doing pump reseals. I contacted him to see if he'd be willing to work on Peugeot Bosch VE pumps, and that's where the project took off. Jeremy was beyond helpful, and is a true diesel enthusiast. Not only was he up for doing the reseal work - but he was also keen on the AAZ hybrid idea and happened to have a donor AAZ pump available for the project! Not only that - but he agreed to document the build with pictures and comments so that I could document the project here on 505turbo.com I've basically edited our correspondence back and forth to build the article - so hopefully it flows well enough to follow: ------------------------------------------------------ These are the pictures upon removal from the shipping box. Seller dismantled the throttle linkage so it would fit in a medium shipping box, so all external settings will need to be set up based on the pump currently on your car. You can see the max fuel screw looks tampered with, but it will be one of the things you will adjust once you get it on the engine.. so it does not really matter. These are pictures of the internals, and they look alright. Varnished from being sat full of fuel, but so far so good. This picture in between the lines shows a hairline "Crack" so to speak on the governor assembly cage. I have broken them before with improperly taking the lids off and getting the throttle arm twisted and jammed. This one was like this when I took ti apart, so it has been opened before. It doesn't look compromised too badly, but I just wanted to note it to you. The stock Peugeot governor assembly is on the bottom, with a 1.9 AAZ assembly on the top. As you can see the Peugeot has a bigger spring with more coils, therefore making it a softer spring rate. As well the Peugeot cam plate first and then a 1.6 TD cam plate second. As you can see it is basically the same as a VW 1.6TD cam plate. Peugeot pump is now fully dissembled and just starting to be cleaned up now. As can be seen the insides are in great physical condition. They are a little varnished as though the pump sat full of fuel for a long time, but it will not affect anything. The important parts look good. The head and rotor look good, as well as the lift pump and its rotor. The throttle sensor that was the plastic thing you wanted pictures of earlier, appears to be broken. So I do not know if it will function for you or not. I was looking at the difference between the Peugeot advance piston and the VW AAZ one. They are different offsets to interact with a different depth cover and what not. So I will need to look at that further to see if we can even use the AAZ spring and piston or not. The springs are physically the same un-sprung length so it seems as though it will work without issue. Peugeot pin and respective spring 1.6TD pin and respective spring 1.9 AAZ pin (nothing to be had here...) and respective spring And the same three again, Peugeot left, 1.6 TD middle and AAZ right. Jeremy’s thoughts: “I am thinking we will use the stock Peugeot advance piston so that interaction with the front cover will remain the same, and I will use the AAZ two piece spring in place of the stock spring. They have the same free length, but the VW spring is much softer, so advance will come on a lot sooner which is generally more desirable with performance tuning in mind.” **Edited correspondence with Jeremy to create the article above ------------------------------------ After finding out how big the cam plate lift difference was, I am confident the decision to pursue the AAZ hybrid idea is going to pay off in a big way when it comes to improving output of the XD3T. Rabin

So i am thinking about buying a red 1988 505 GTD (XD3TE) with a seized motor, and replacing it with another motor from a 1987 GRD diesel wagon (XD3). I'm wondering if anyone knows what the difference is between these two motors? Is it possible to Convert an XD3 to an XD3TE without opening the engine, and just swap the turbo bits over (Turbo, intercooler, exhaustmanifold etc.)? Ludvig

I bought this pump as a spare for my car, but I am wanting to get another pump rebuilt with some modifications and it seems like a waste to pay to get this one redone just for the modifications I want. This is the 9mm plunger version used on 5-sp XD3T cars, and it was very recently rebuilt (less than 5K miles) before the car was parted out. Previous owner spent over $1000 just on the rebuild alone. I'll even throw in the glow plugs that were done at the same time. I have stored it with ATF cycled through it as per the local diesel shop. If there's interest I'll get some pics up of it. Rabin

Hi guys, I've been doing a lot of research on my TD and I'd like to rebuild a spare set of injectors with some Monark SD 265 nozzles, with the break/pop pressure set to 160 bar. I've found one of the only sources for the nozzles to be www.mercedessource.com - but they only sell the SD 265 nozzles in sets of 5 or 6. If there are 2 more people interested we could buy 2x 6 sets and each get a set of 4. Please post / PM / contact me direct if you're interested in getting a set. (Or if you have a better source for the Monark 039 305 128 nozzles.) I'd use Bosch SD 265 nozzles if I could find a NOS set of French or German made ones. Rabin