Hoorah, finally got myself a 2.2 Hdi, but its a mess......

[GingerMagic]

Good evening everyone.

Good news, I have manage to bag myself a "bargain" 2004 406 2.2 Hdi Executive Estate and I was very exited.

Then when I picked it up I realised it was cheap for lots of reasons. The MOT has just expired and I don't think it will pass the next without a fair amount of work.

I have looked up a few problems on the forum so I have some ideas as what the faults are and how to fix them.

Airbag light is constantly on, may just cut the wires under the seats and use chocolate box electrical connectors instead.
Blower not working, hope its the modulator - I will check when sunny.
Drivers window goes down and only occasionally goes back up but it is a GLX switch, not the executive one with the white dot.
Fuel flap warning comes on the mfd everytime I pull away or stop, even though it is definately shut, this beeping is a pain in the arse..
Anti-pollution fault - I thought it might have one 'cos of the price but maybe this is due to the false alarm fuel flap warning throwing in the cleaning stuff ( which is now empty )
Would not go more than 60mph on motorway and down to 40mph on the hills - I hope this is the fap and not a turbo fault ( I can hear whistling but drowned out by a rasping noise? )
Back brakes are shot - I think I can do this myself - kits available for around £70.
Fair few dents and scrapes, possible mild front end knock but to be fair I will put a few dents in it myself...!!
I fixed the remarkable over revving when shifting gears by slackening the throttle cable by one notch - easy.
Lastly, no service history at all, so have booked it in for a cheap MOT just to see how the usual drop links and cv's are wearing.

There are probably loads more gremlins to sort out - I have spoken to some members regarding de-fap and remap already, nice to have priorities.

Most other things seem to work i.e cruise, seats, gadgets clutch and most of the running gear, surprised that reverse is top left not bottom right.

If anyone can help regarding the fuel flap problem and lethargic perfomance then I will be most grateful.

This was meant to replace SWMBO 306 xudt as need a bigger family car and my 406 Hdi 90 still smells inside like a wet dog in shoe cupboard - can't get rid of that smell but car is useful for dump trips and just moving other people stuff for financial gain. Not good enough really for the rest of the family but fine for me.

Wish me luck....

[Doggy]

Welcome to the club.

Got yourself a bit of a list there, but if you keep at it, I don't think there's anything we haven't seen before.

Unfortunately you're some distance away from the point of view of popping round, but I'm happy to help any way I can.

Pictures?
Mileage?
Did you ever get your Galletto?

[GingerMagic]

Hi Doggy, didn't get the Galletto as my Hdi 90 was a Siemens so hard to find a remap.

Mileage is 179,000 - much the same as the 90, but judging by the worn out door seals at waist height I guess the car was used for ferrying people around.

I hope to meet up with Finchy to do the Fap work if I can get a trailer / dolly for a couple of days.

I drove the car back from Birmingham to Bournemouth and apart from the lack of power it was a nice drive, very comfy.

I will take a few snaps but car does look like it was parked amongst a heard of restless cattle for a while.....

MOT booked so will keep updating the thread, blower is a priority at the mo.

[dieselink]

hi m8,had trouble with my blower when i got my 2.0 hdi in april,take out fan first,its under the glovebox and try direct from battery to see if its that first m8,mine was the resistor was fooked also was getting no power to resistor,got and new resistor from e-bay for 30 quid and had to re-wire to resistor,works fine now.also i find this site cheap for parts and free delivery.http://www.carparts4less.co.uk/ dont know if thats of any help m8,but if u want advice about the blower,i would be glad to help,as it took me a few weeks to get sorted and leant a lot about it.my drivers window doing the same as yrs,so will watch yr posts for some advice before i strip it down.good luck with mot m8.

[Malc]

Don't even attempt to remove blower motor until you've verified 12v is leaving fuse-box to unit.
Had similar prob and it was the b-m contact in the ignition switch that had gone.
See my posting on how I fixed the problem without new switch replacement or additional relay.
Still working perfectly since modded.

viewtopic.php?f=3&t=15481&p=149716#p149716

[GingerMagic]

Thanks for the link Malc.
I was going to check the fuses first but was unsure which fuse - now I know.
If fuse is good I will check module by removing small screw in passenger compartment.
I don't have a voltmeter ( just looking on eBay for one ) so used a household lightbulb fitting with stray wires...
Bulb works in a house light but not when sticking in the two plug connectors next to the fan motor.
Perhaps I should wait for voltmeter first then go from there, but if I find an inline fuse in the shed somewhere I will try your fuse bypass trick.
I'll keep you updated....

[Doggy]

You might finf this useful too. http://www.petrila.net/pug/Service/index.htm

[GingerMagic]

Good news everyone, I now have a working blower. Thanks to everyone who gave me advise and guidance.
I checked fuses in engine bay, all fine. Checked fuses in drivers side and all good, coudn't find F40 but found the letters A - F on lower rear fuses and figured F was a 40 - it was a 15 but intact.
Found the module by looking under passenger footwell ( carpet was removed already for some worrying reason ) and couldn't get a small enough socket on the retaining bolt so resorting in giving the connectors a wiggle and hey presto - cold air in the chops..! Couldn't then turn the fan off so had to wiggle connection a bit more and now all is working as it should - until I go over a bump anyhow.
Airbag connectors next on the list - can I do this with engine running or is this a recipe for disaster..?
Is it possible to cut connectors off and wire in with spades or chocolate box connectors??

Dieselink, I had a problem with the electric window switch in my Hdi90, and thought the worst when it started playing up. Had visions of removing doorcards and mechanisms etc, but simply replaced the switch from a scrap 406 and it worked fine. I will do this with the new 2.2 but just waiting for replacement one ( with a white dot so I can fold the mirrors in ) from an executive, not many around though. Plenty of normal ones on eBay for anything from £10 - £45.

MOT booked in for next Friday ( MOT and Valet for £24 - thanks Groupon..! )

[lozz]

Re:Air bag connectors

Dont touch them with the engine running!

ign off,is best

[GingerMagic]

Thought as much, only there is no way to check if the " playing " with the wires has worked until turning the ignition back on, then I guess you would have to wait another 15mins or so before " playing " again if it hasn't worked.

Will look at the pre-tensioner first as this seems a common fault on the forum.

[Doggy]

With mine, it's always the passenger pre-tensioner connector.

[GingerMagic]

Story so far, car was MOTed today with a cheapie MOT special offer and I thought the worst. Turns out that it only failed on front disc imbalance, so replacement disc and pads done by the MOT people. They must like 406's as they seemed to ignore the airbag light and seriously binding rear brakes, anti-pollution fault etc. Good news indeed. It must mean drop-links and CVs are good too.
Secondly, I sent a letter to the previous owner of the car using the name on the logbook. I got a phone call 2 days later from him discussing the cars history, namely a replacement head and cambelt 30,000 miles ago. He loved the car very much and only got rid ofit as the fuel flap warning was flashing and was quoted so much to fix it along with the anti-polution. He is now a little more sorry he sold it as I mentioned how much to De-FAP it. He should have checked out a reputable forum.......
Any how, this means I can legally drive the car even in its current state and graually fix things bit by bit, new electric window switch for Executive is in the post, chap on eBay has identical car with mint bodywork being stripped, only 10miles away.
seems the sun is shining after all.
Read somewhere about a switch / connection cleaner, any ideas where I can get some?? Hope this will fix the airbag light, if not I will have to wait for diagnostics.
Photos and updates to follow.

[lozz]

Good result that mate, well done

its nice of the last owner to give you a run down of its history,
especialy the cambelt, atleast you know it good for plenty more miles,

[GingerMagic]

Yes it was, didn't think he would. Goes to show that it worth a shot for any new car I suppose. Seemed a decent fella too.

[Doggy]

Sounds like you're winning, well done!

Try unplugging / re-plugging the pretensioner connector a few times, I think it will give you a temporary solution and proof of how to get a permanent fix......