Definiative XUD9 conversion Thread

[Norledge]

Guys, 

I've just done (well doing) and XUD9 swap into my 2001 M49, having struggled to find any full info on it before I did it thought i'd post everything in one place!

DW8 (2001) to XUD9 (1996 - Bosch fueling)

Engine Mounts - Use XUD top ones, DW8 'dog bone' lower

Engine loom - Use DW8 loom, but change the following connectors - Oil temperature (front centre of the block), speedometer pick up (top of differential) and oil level sensor (rear centre of block). You'll also need to remove the fuel pump plug from the XUD loom and splice it into an ignition live (one of the green wires that goes into the blue fuel pump plug on the DW8 loom). Glow plug main power is also in a different place, but the DW8 one will reach the XUD plugs if routed correctly behind the fuel filter.

Clutch - The 306 clutch cable is required, make sure you fit this BEFORE you drop the XUD in!

Cooling - Use the 306 Radiator, and all coolant pipe EXCEPT heater matrix pipes - the berlingo ones WILL reach the XUD outlets (just!)

Fuel Pipes - Keep the primer bulb from the 306, join this to the smaller diameter pipe on the Berlingo. For the return you'll need to snip the connector off the DW8 engine and join that.

Air Intake - You'll have to custom make this, nothing to complex!

Driveshifts - Berlingo shafts fit fine

Exhaust - Use the full 306 exhaust - you will need to modify the rear box and extend the centre section (pictures to follow!)

Think that's everything, its an easy enough swap if you plan it well. Managed mine in a lazy weekend.

Any questions feel free to post below or PM me

[eddy_gti6]

Sure this will help a few people out as seems to be a common conversion on these now. Good write up.

Exhaust I would personally use the 306 exhaust too but extend the middle section

[Karl1989]

I used all 306 mounts just moved the fork on the subframe