406oc.co.uk

Hi,

I was thinking that it may be a good Idea to list all the know faults with the HDi and cost of the part to fix the problem (including symptoms of the problem): -

REAR ENGINE MOUNT

Symptoms: - Vibration when accelerating and also slight vibration when idling at the lights

Parts: - PT180933 Flexible bush £9.72

NOTE: - Information regards to a HDi 110bhp 2.0 (V reg onwards)

Andy

xplosiv wrote:
I was thinking that it may be a good Idea to list all the know faults with the HDi and cost of the part to fix the problem (including symptoms of the problem): -

All the known faults?! You'd be there all day!

good thinking mate cracking idea

Andy

EGR Valve

Symptoms: - Black smoke, when accelerating and a very slight dip in performance

Parts: - cannot remember the price (best guess £90)

NOTE: - Information regards to a HDi 110bhp 2.0 (V reg onwards)

Andy

Andy

Rear Springs

Symptoms: - Back of Car looking lower on one side, or just not sitting right. Quick check would be to see if a small section of metal at the bottom has broken off.

Parts: - Again cannot remember (best guess £90)

NOTE: - Information regards to a HDi 110bhp 2.0 (V Registration onwards)

Andy

well i aint got a HDi but my dad being a pug master tech knows all about the common problems
ill make a list for you:

Lift pump failure
High pressure pump failure
EGR valve failure
Acclerator pedal possition sensor failure
DMF breaking up or exploding for some unknown reason
Rail pressure sensor failure
Injector's leaking or failing
Cooling fan failure
ECU failure (not common but has known to happen)
Turbo failure
Split intercoolers

BOTTOM PULLEY FAILURE!!!! (ticking noise when cold, or after a long run, followed by very loud metallic clicking at anything above 1500RPM) replacement required urgently or suffer the consequences)

Rear discs/shoes combo prone to trouble.
Air Con Condenser Failure (D9) due to leaves/bits getting stck in fan cowling at the bottom.

And again,

• Throttle Position
  Cooling Fan

....each requiring Diagnosis and replacement.

BSI on those nasty D9's !

High Pressure Diesel Pump Failure:-

- Siemens pump = £514 + VAT from Peugeot
- Set of followers = £280 from Peugeot (Bosch replacements now available from EuroCarParts much cheaper)
- Cambelt
- Tensioners (x2)
- Bottom Pulley (not essential but hey, if you're spending £1200 another £50 won't notice)
- Gasket Set
- Head bolts
- Cambelt covers
- Labour (a good mate at £120 all in!)
- Train ticket to work!
- Fuel filter
- Oil change
- Oil filter

Who said an HDi 90 would be cheaper to run than a 1991 MK2 Golf GTi over 30k miles a year ???? OUCH!

....... forgot to add in the MAF at £72.

Replaced mine and got an extra 4MPG and much smoother running and a tiny amount of extra zip (if you can use the word zip about an HDI 90!).

Eeeew..Are you saying the pump failed and took the cam belt with it?

I have kind of the same dilema as you here, I bought the 406 to try and save £450.00 a year on fuel but consequently spent nearly £1,000.00 on repairs on said 406

Yeah, the fuel pump completely siezed after something inside broke and basically jammed it. Since it is driven from the cambelt via a toothed wheel when it stopped (at 90mph) the belt came off having bent the tensioners. Luckilly for me, although you could see where the valves made contact with the pistons, they didn't pierce anything and simply bounced right back up into the head, shattering the followers and therefore staying pulled up into the head via the springs to avoid any more damage. They weren't even bent so we simply reground them back in whilst the head was off. Apparently this is all by design to protect the engine against belt failure damage.

I think its just one of those "unlucky" things as I don't think that these pumps are "known" for any particular high failure rate - but hopefully this thread will give some indication if others are having the same problems.

Other than that it has been 100% in 19k miles since September 2006 (although I changed the MAF as the original one was filthy and MPG dropping slightly) giving about 44.8mpg according to the computer at 90mph on motorways - which isn't exactly being gentle on the car!

I myself am convinced that high pressure pump failure almost always follows a dose of Petrol through the system at some point in it's life.

And your right the cam/followers and cam caps are designed to break and protect the valves to some extent.