Puggy Allsorts!

[Pohaku]

Hello folks...

I've just bought my first pug (1997 406 1.9TD LX), but unfortunately I feel I've been ripped off by an unscrupulous 'private trader'. I test drove the car and it seemed okay, and so I ended up buying it - I know very little about cars, and yes - I'm a bit impulsive! Anyway, it ain't right (see below) and I was on the verge of selling it for spares/ repair on eBay, but I've decided to try and make a go of it and revive her...

I don't expect a complete 'how-to' guide here, I'm pretty good with google and I'm going to approach each problem in turn and try to fix it up in my own time. However, these forums are obviously read by some very knowledgeable people, so I thought that if I paint a picture then someone might have some advice or pointers. Here are the problems I intend to tackle (in no particular order):

1) Brakes... I have to press the brake pedal about 75% of the way in before I get anything from them. They do stop the car when I get there, but it'd be nice to get a better response. More worryingly, when braking lightly to a halt, the car seems to 'rock' - as if I am rhythmically pumping the brake pedal and not pressing it smoothly. My initial thoughts are warped brake discs? Any advance on that?

2) Starting up... After being stood for a few hours, it's a swine to start. It turns over well enough, but doesn't seem to 'catch' - pumping or pressing the accelerator doesn't really help, and I find myself having to warm the glow plugs (switiching on, then off then on, then off then on) several times before I can it to 'catch' and start ticking over. Once the engine is warm/hot, I can turn it off and re-start it with no problems. I am thinking that new glow plugs will remedy this?

3) Cutting out... still not diagnosed this one fully, as I've taken it off the road until other things are fixed. When pottering around town at low speed, in gears 1,2, and even 3, at up to 15mph, no problems. Once I get up to 20mph+, then I brake for a junction, or a roundabout, the engine turns off when I press in the clutch and brake as I come to a halt. It restarts with a turn of the key, but it's worrying because it can happen as I am slowing down whilst on a bend, even if I am doing up to 20mph as I press the clutch and brake - this causes the power-steering to fail, as it switches off and the dashboard lights up. It only seems to do it if I am in 3rd or 4th, and I am braking to an eventual halt without going down through the gears. I have avoided it a few times by quickly changing down all the way to 1st, but this isn't practical at every junction or traffic light! I have no idea what this will be - maybe the glow plugs will remedy it?

4) RPM counter... it's all squiffy, showing the engine idling at 3,500 and well into the red when cruising. I can tell from the sound that the engine isn't running this high, as the frequency seems about normal. Not looked into fixing this, yet.

5) Noisy engine... it sounds like a transit delivery van. Not an unhealthy sound, but just like a very loud, 'loose' sounding diesel. Again, I don't know if this is normal (my first diesel), if it is just down to age (130,000 miles) or if it's a sign that she's terminally ill! Any ideas?

6) Warning light... the light that comes on to indicate the glow plugs are warming up when I switch on (looks like an engine with a weird 'K' in the middle' has come on a few times when cruising at 60mph or so. Didn't especially do it under load or braking, and never stayed on more than 30 seconds. Again - new glow plugs might fix this? Or is this a sign of something very bad?

That's it for now - I might find other things as time goes on. Has anyone any advice on what to look at first, or which jobs I can attempt myself whilst getting garage to do others? I must point out I'm on a low budget, and looking at maybe a few months to get through the issues listed above!

All pointers appreciated!

Pohaku

[mjb]

1) Brakes...

The travel on the pedal sounds dangerous. Checked the fluid level and pads? If they're ok I'd be thinking about the master cylinder, but I don't 'get' hydraulics...

2) Starting up... ... glow plugs

Do a search on here - there's a few people who've had similar problems

3) Cutting out...

I'd suggest checking out the throttle position sensor and idle control valve/solenoid

5) Noisy engine... it sounds like a transit delivery van.

The TD engines do sound a bit agricultural. 130,000 miles is nothing for ANY 406, especially the TDs which can easily clock up 1/4mil.

6) Warning light... the light that comes on to indicate the glow plugs are warming up when I switch on (looks like an engine with a weird 'K' in the middle' has come on a few times when cruising at 60mph or so.

The glowplug light should be a spiral iirc. The light you describe is the engine management light. I'd get the fault codes read.

[steve_earwig]

>deletes nowhere near as useful post<

1) could be air in the sytem, if you pump the pedal does it rise? Waped disks too, more usually the rears.

5) Doesn't the 1.9 have those awful old-fashioned bucket & shim adjustable tappet things?

You've got things in the right order anyway, make sure you can stop it first!!

[steve_earwig]

and, before I fall asleep

7) it probably needs a new timing belt.

[mjb]

1) could be air in the sytem, if you pump the pedal does it rise? Waped disks too, more usually the rears.

Forgot I meant to say something here. If the steering wheel judders under braking, it's a front disc warped. If there's no feedback from the steering wheel it'll be at the back.

[Pohaku]

Thanks for the feedback, guys... feel a little bit more confident already!

The steering does judder under braking, although only when braking from higher speeds (45mph+). I don't think I'll be up to changing brake discs anyway, so I'll get the garage to confirm the problem before they do any work here.

As for it needing a timing belt - is that based on one of the problems I have described, or is that just because it's done 130k and the condition suggests that previous owners probably didn't bother? I understand that a timing belt going can cause major damage - is there anyway to actually check if it needs a new one, or should I just get it done anyway? Ballpark figure for that, anyone?

Lastly - someone mentioned adjustable tappets, in relation to my comment about a noisy engine. Umm... I have no idea what a tappet is anyway, but are you saying that there is something I can adjust to remedy the noisy engine?

Sorry for sounding a bit ignorant, but my experience under bonnets is very, very limited!

My current plan is to buy and fit new glow plugs, as it's not too expensive and I'll feel a lot more positive about the car once it's starting up first time, every time! When that's done, I'll probably be back for advice (or possibly while doing it, as my googling tells me that changing the glow plugs is a swine of a job...)

Thanks again guys...

Pohaku

[steve_earwig]

The steering does judder under braking, although only when braking from higher speeds (45mph+). I don't think I'll be up to changing brake discs anyway, so I'll get the garage to confirm the problem before they do any work here.

Don't forget, you still need to sort out the pedal travel - siezed callipers, duff pads, air in the system, impending doom... Warped disks are a nuisance and may eventually kill the wheel bearings but it'll still stop. Start by looking at at the pads and work from there.

As for it needing a timing belt - is that based on one of the problems I have described, or is that just because it's done 130k and the condition suggests that previous owners probably didn't bother?

The latter, your car sounds rather ignored. Unfortunatly, it'll kill your engine if it goes. You should be able to get the top cover off and have a look but, unless it's brand new, it probably won't tell you a hell of a lot.

Lastly - someone mentioned adjustable tappets, in relation to my comment about a noisy engine. Umm... I have no idea what a tappet is anyway, but are you saying that there is something I can adjust to remedy the noisy engine?

I'm afraid it's a little more complicated than that, lots of measuring, cam off, you have to buy the shims according to the measurements you took, blah blah, it's do-able but a pain. It's not crucial though.

The glow plugs shouldn't be too hard, maybe things might be a bit tight but take your time. Sorry my reply looks a bit "doom and gloom", the thing is your car's really not going to self destruct on Tuesday but it's stuff you should get sorted out before too long.