My new 406 project....

[GingerMagic]

Well, thought I would introduce my new car to the forum. I picked it up on Friday, parked in on the drive and declared it as SORN until I get it up together

Its an '02 registered 406 2.2Hdi Estate - the GLX version in ' China Blue ' ....... On the plus side it has FSH, key code, spotless interior including the headlining and the body panels are really good ( apart from N/S rear door ) and the doors shut with a nice 'clunk' so seems good so far, right?

Put it on PP2000 earlier and here is the rundown.

Airbag fault - trigger 1 and 2 drivers side, diesel additive low, EGR valve flow is wrong and turbo pressure too high, swirl flow diaphragm doesn't move. Couple of other minor faults , noisy pulley etc but nothing to worry about. I'll send the Comms unit off to the chap that John used while I'm attempting the de-fap and EGR blank and simultaneous swirl diaphragm.

Lastly, the brake pedal is really hard when you first brake but after about a second the pedal starts to give a bit and the brakes work really well - would this point to a vacuum leak?

Pictures and subsequent updates too follow

Kelv.

[V6Exec]

EGR valve flow is wrong and turbo pressure too high, swirl flow diaphragm doesn't move.

...

Lastly, the brake pedal is really hard when you first brake but after about a second the pedal starts to give a bit and the brakes work really well - would this point to a vacuum leak?

That combination confirms you have a vac leak

The vacuum decreases the turbo boost - no vacuum = turbo pressue too high

Swirl diaphragm not moving = no pressure differential across the unit - again a vacuum issue

[GingerMagic]

Thanks, is there a common place for the system to leak or is it pot luck.... I guess if I change the swirl flap ( I have a spare ) then see if this is causing the leak first.

[Doggy]

Swirl flap diaphragm sounds favourite. Plug the vacuum pipe to it and see if that sorts the overboost and servo.

I'm thinking the flow restrictors should have prevented it loosing enough vacuum to affect the brakes, but maybe the pipe work's been swapped around by someone trying to fix it.....

[GingerMagic]

Just read the last MOT advisories;
1. Engine cover obscuring components in the engine
2. Under-tray fitted obscuring some underside components

Thats it.

[rwb]

That looks very nice

What bizarre things to put on an MOT.

[jasper5]

Agreed, looks great, you'll soon have it up to scratch

The mot guys write that on the advisory to cover themselves in case there is an accident caused by something they couldn't check because parts were in the way.

[Doggy]

Looks pretty smart for the money, I think you've done well.

Still prefer China Blue to Grandad Green.

[dirtydirtydiesel]

I'd say you stole it for £400 , the doors look straighter than mine, F.W.I.W I like the colour very close to mine & you old one
& you'll soon have all the prob's sorted + 180bhp with nice alloys 'n' leather (git)
Best of luck bud DDD.

[jonsowman]

Nice one Kelv, maybe the colour will grow on you!

Easy way to test the swirl diaphragm - pull the hose to it off from its EV (it's under the airbox on Coupes but I always forget with saloons/estates) and just suck the end of it (maybe give it a quick wipe first ). If you suck on it then hold your breath, the rod should stay retracted fully and not creep forwards. It's a pain to get to, recommend removing it on its bracket as this makes the job a bit easier.

If it's not that, next suspects are the turbo and swirl EVs.

Your brake and turbo problems are likely to be solved by fixing the vac leak so ignore those for now.

With regards to the crankshaft pulley, this seller on eBay is selling genuine new ones for £50 at the moment which is a steal, have just bought one (thanks to nutski for this!).

Best of luck and let us know how you get on!

[GingerMagic]

Thank you everybody for your support. The colour is growing on me - it helps that is generally very clean inside and out.

De-fap is first on the list, Comms is second, EGR is third when I find a 1.2mm and a 3mm blanking plate. Will a 1.2mm each end of the EGR plumbing be strong enough, as I plan to keep the pipework in place for future MOT reasons..

[Welly]

Let me see........

Dodgy Blue Colour - Check
Mini-Cab seating solutions - Check
PP2000 faults-o-plenty - Check
Funny noise - Check
Toe Hitch - Check
Complex Vacuum leak - Check

Top purchase Ginger you've bought the perfect 406, well done, looking forward to progress updates

[GingerMagic]

I would feel cheated if I bought a 406 that had 'nothing' wrong with it....

[nutski]

EGR is third when I find a 1.2mm and a 3mm blanking plate. Will a 1.2mm each end of the EGR plumbing be strong enough, as I plan to keep the pipework in place for future MOT reasons..

Looks good Kelv!

I might have some of these for you in a couple of weeks if you are ok for that long, i need to deFAP by brother's Coupe and has already had the EGR blanked with really thin plates but all pipework removed too I've got some Nico pipes coming for it with some hefty blanking plates to swap over, can post the thin ones to you to slip under the original pipework?

[gumby6371]

The swirl actuator is much easier to get at with the egr pipe out of the way so I'd tackle both jobs at the same time. The EV for it is mounted just below the egr pipe, follow the vac pipe down from the pump visible in your engine bay pic. With the airbox out there is plenty of room.