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Old 16-08-12, 11:32 PM   #1
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Unhappy Boxer running problem

Intermitant fault with a 2.0 51 plate boxer. It was cutting out about 20 seconds after starting. code reader failed the throttle pedal and both cooling fans. I replaced the throttle pedal, corroded fan relays and number 2 fan now works ok, number 1 fan needs a new motor. I allso repaired the fuel pump relay wiring. Now starts and will run all day on tickover but still cutting out some times when reved up. Not allways, its very intermitant.
Code reader now says 480, fan1, 0191 unknown error, and 404 egr valve.
When the engine cuts, there is a relay type click from behind the glove box and the engine will not restart unless the ignition key is turned off for a little while. I blocked off the vac pipes for the egr and am going to fit a blanking plate to the manifold, but would not have thought the egr would cause this.
When it cuts out, the shut off solenoid and fuel pump are still geting voltage.
Anyone got any ideas?????
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Old 28-08-12, 09:50 PM   #2
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You need to have this checked out by a specialist
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Old 29-08-12, 09:52 PM   #3
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Thanks for your reply MadV, and for taking an interest in my problems. Two Peugiot dealers have looked at it, The first a main dealer had not got a clue. They just wanted to throw bits at it. A big bill for wasting my time. A small repair only Peugiot workshop had a look but were only able to confirm what I allready know, but their bill was very reasonable for the time they spent on it. They sugested trying another throttle pedal. I borrowed one off another van but just the same. Two so called specialists had a go without any luck.
I blanked off the EGR valve and replaced the fan and cleared the ECU memory Now just showing 0191 unknown error. but it started and ran OK. Ran it for a few days and all seemed well. Did a 200 mile trip at the weekend, went like a bird. On the way home went into limp home mode a few times, but cleared after a few seconds. Next day started, drove 100 yards then cut. now back to starting and running for about 5 sec's before cutting.
I was just hoping someone on the forum had had this problem, and could point me in the right direction.
I may just scrap the dam thing. I have wasted enough money. Peugiot's used to make the best Diesels, but since they went common rail they have been junk. I should have bought a Transit.
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Old 02-09-12, 10:23 PM   #4
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P0191 is a fuel pressure code. Have you done a leakoff test on the injectors
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Old 06-09-12, 11:11 PM   #5
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Thanks MadV. Pity I am I cannot get the van to you. You seem a lot more clued up than the so called specialists in my area. I am on holliday at the moment, but will check it out as soon as I get back next week. Thanks again. Shabby.
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Old 09-09-12, 10:10 AM   #6
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My problem is affording the kit. I have PPs(I know how to use it) which I will not change until a couple of years down the line. I also have the breakout box and various dealer tools including low pressure test kits.
The one thing I have not got is a dummy fuel pressure sensor kit which can test out the pressure at the sensor. Its about a grand but I would hardly use it, so why should I pay a grand for a bit of kit which is not going to pay for itself.
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Old 16-09-12, 11:25 PM   #7
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Well MadV, ten out of ten. I was wondering how I would do a leak test when the dam thing cut so quickly after starting, but I disconected the spill return pipes from the injectors, switched on the ignition, and got a spray of fuel from number 4 injector spill return on the top of the injector.
Strange that the fault has been intermittant though. Thats why I never suspected an injector.
Now, as the van has a gearbox problem as well, jumping out of 2nd and 5th ( I think its the bearings on the gear shaft) do I lash out for an injector or cut my losses???
I will see how much the van breakers at Witney want for an injector, and how much to get mine done and go from there.
Anyway, A big thank you to MadV for your help and advise. pity you are so far away from me. I could have saved a lot of money and time if I could have got it to you in the first place. Regards Shabby.
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Old 17-09-12, 11:15 PM   #8
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Injector should be about 130 plus vat. Gearbox - make sure that 2nd and 5th is the only problem and no bearing noise. Remove it and ask a gearbox specialist to repair it. Compare the cost to a newer van which is of unknown quality
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Old 19-10-12, 09:24 PM   #9
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Well, here is the latest on the saga of my van. T&B motors, the van breakers at Witney oxfordshire supplied an injector at reasonable cost. I fitted it, checked for injector leak off, all seemed well. Started it up and the dam thing cut again after a few seconds. I was tempted to scrap it, but I have spent a lot of money on it doing up the brakes and suspension so I will carry on.
I will try to make up a fuel presure test guage/adaptor to see what is happening with the fuel pressure when the engine cuts. Anyone know what the fuel pressure should be??
I asked T&B motors if they had a gearbox, but they did not. They say its a comon problem. A local garage get their gearboxes done by a "Fred in a shed" who just mends gearboxes. He has the service tools for these box's so if I can sort the running problem out, I will let him have the box. Regards to all, Shabby
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Old 20-10-12, 11:31 PM   #10
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Any faults in it..
#
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