406oc.co.uk

Hi,

I bought my X reg 406 HDI 110 estate a few weeks ago for little more than scrap value and have been doing a few jobs to get it back to good health.

It's done 249,000 miles but I have an almost complete service history, it's been well taken care of in it's life despite a lot of bumps and scrapes that make it look it's age.

So far I have replaced the n/s front inner tie rod and bottom arm rear bush, fitted a new MAF sensor, changed all the filters, oil and power steering fluid. removed the previous owners duct take from the sills and put some new clips on the rubber seals.

Got a clunk now from the rear too, a quick look and shake of the suspension seems to be pointing towards those funny plastic drop links, should be easy enough.

It was still down on power after the new MAF sensor was fitted so I expected a boost leak, I was right, the MAP sensor on the intercooler is snapped and the nipple that the hose connects to on the intercooler it's self has been snapped off. I have botched this up temporarily with duct tape and cable ties but will need to fix it properly as soon as possible. Any idea if i'll be able to fit one of those connectors people use to plumb in a boost guage to fit a new hose to the intercooler or am I going to need to change the intercooler its self?

It's making a nasty ticking noise at idle from the drivers side of the engine, sounds terrible with the window down. I expect this to be the crank pulley so am planning to replace it but there seems to be a lot of different types and i'm not sure of the correct pulley or the correct belt as there seems to be a few different lengths of belt too.

Does the type of pulley and aux belt I will need depend on the age of the car or is it more random? Any body got any idea of the correct part numbers?

I'm used to Rovers and MGs where there's only likely to be one part available for your car, Peugeot seems to have changed things daily and finding the right part is much harder.

Thanks for any help.

E D B

Hi EDB, welcome to the club - sounds like you have got your hands full but you are on the right track replacing the parts that are the weak spots.....

I think if the spout from the intercooler is solid enough then you can just clip a small pipe onto it and plumb the MAP sensor into that - most aftermarket boost gauges will also come from this point but with a T piece instead.

If you sign up to Service Box ( it's an online Peugeot parts catalogue ) you can type in your VIN number for the correct part and specification.
You will need to make up a business name and details though - but it's free to use for the basic needs.
Infotec Peugeot is also a useful online source for the owners manual, if yours is missing.

Good luck with your ongoing project, and it's a legal requirement to post pictures if your car here...

Thanks, I have signed up to service box and now know the correct part number for the crank pulley. It doesn't seem to list the aux belt though so I still have some investigating to do, somebody told me it matters what type of air con compressor is fitted?

The problem I have with the MAP sensor is that there is no longer anywhere to clip a hose on to the intercooler any more, just a small round hole. I have seen where people have drilled a hole in a pipe and fitted a connector for a boost gauge so may look in to that as a solution otherwise i'll be stuck with the eml on forever.

Are you sure you want to see pictures? The dents and scratches this car has could upset a few people

I'll post some pics soon, maybe concentrate on the interior, that cleaned up pretty well and you wouldn't think it had driven to the moon.

Hi Edgar and welcome aboard.

It may be simpler to change the intercooler - plenty of them in scrapyards one from any HDi 110 or 2.2 HDi 136 will fit so long as it's not from a coupe. Worth sorting it out properly as your car has an ecu controlled wastegate and the fuelling will be all over the shop without an accurate MAP value. (My bro's old 110 Hdi had the same issue when he got it - well worth fixing).

Take your old aux drive belt along when you pick up the pulley. The bolt holding the pulley onto the crank can tight, various methods for this, my favourite is to get someone to stand on the brake pedal in 5th gear and use two long straight extension bars on the socket, so you're twirling your breaker bar outside the wheel arch.

Aux belt has an auto tensioner - you need a 15mm ring spanner, (preferably with minimal offset since the nut's really near the inner wing). Not being a muscle-man, I need an extension of some sort to hold the tensioner off comfortably with one hand while you get the belt disengaged.

Thanks Doggy,

Just had a trip to a couple of local scrap yards and found nothing with a compatible intercooler, there was one 2.2 hdi but it had no front end to speak of, 3 other diesels but all 90s so no intercooler and a couple that run on that odd petrol stuff. none of the estates were in the same colour as mine either so no chance of getting a replacement for my very badly damaged rear passenger side door.

Not a completely wasted trip though, i did get the MAP sensor from a citroen C8 and they didn't even charge me for it.

I'm going to try and repair the connector on the intercooler, it will only cost a couple of quid so it's worth a go, if that fails then i'll look a bit further afield for another intercooler.

Now I just need to find out if I have a delphi or sanden air con compressor and I can get my aux belt ordered.

Any idea if the faults will clear once the map sensor is replaced or will I need to get them cleared on a PP2000? Probably best to get the faults read anyway, there's probably more.

Welcome to the forum
Good luck with the project, that's only done half its expected millage
Post up your location, there could be someone nearby with pp2k
Try ebay or on here for a intercooler, you should get one for £20.00.

There's a good chance the fault(s) will clear, but not instantly. You will probably need to do 3 'journeys' with no current fault, the the ecu should then change it from a 'permanent' to 'intermittent' fault and cancel the EML. Doesn't always work and you may need PP2000, but it costs nowt to try.

('Journey' means a cycle of starting and stopping the engine, leaving ignition etc. off for long enough for the engine ecu to 'go to sleep' before repeating).

Good luck.

dirtydirtydiesel wrote:Welcome to the forum
Good luck with the project, that's only done half its expected millage
Post up your location, there could be someone nearby with pp2k
Try ebay or on here for a intercooler, you should get one for £20.00.

Thanks,

I had a bad experience with a 307 hdi company car about 12 years ago that really turned me off the idea of getting a peugeot but when I was offered this car I couldn't say no. I have been pleasantly surprised by how good it is to drive, it doesn't feel like a 17 year old car that's traveled so far and it's will hopefully get even better when i'm done.

Going to try and repair the intercooler, if it works then it will be a cheap fix and i'll see how it lasts, if not then i'll look for a replacement.

I'm in Chester, if there's anybody nearby who would be willing, that would be great.

Doggy wrote:There's a good chance the fault(s) will clear, but not instantly. You will probably need to do 3 'journeys' with no current fault, the the ecu should then change it from a 'permanent' to 'intermittent' fault and cancel the EML. Doesn't always work and you may need PP2000, but it costs nowt to try.

('Journey' means a cycle of starting and stopping the engine, leaving ignition etc. off for long enough for the engine ecu to 'go to sleep' before repeating).

Good luck.

Thanks for the info, I suppose I will just have to wait and see.

Been out today having a play and have managed to fit a new nipple onto the intercooler and fitted a working MAP sensor, took it for a drive and it's like a new car, it can even manage to accelerate up steep hills.

I'll give it a week and see if the faults clear then it's time to disable the egr valve and block it off.

Making a little bit of progress with every little job I do, it feels good.

Well done, keep uo the good work.

Well, it's been nearly a week and the engine management light is still on

Have been on a few longish drives with good gaps between to let the ecu sleep but am driving to bolton on friday and back saturday so if its not cleared then i will have to get the codes read and reset. will at least tell me if there are any more faults i need to rectify.

the car is driving great now, just a little rattly at idle and the knocking from the near side rear that i'm planning to sort out as soon as possible.

That's a shame, can't be anything much if it's driving well.

I have ordered a cheap chinese PP2000 clone thing, hopefully it will do what it's supposed to.

It cost almost as much as the car but I can always sell it again when I no longer need it.

Go luck with the pp2k, it can be a pain in the backside to configure & run