1.9td questions

[xsaras4ever]

Hello to all - can we pick your brains on the 1.9td engine.

We bought a Peugeot Boxer van yesterday - cheap - belches black smoke - owner says its probably the turbo and wastegate.

Its a 2001 1.9td van - no intercooler.

We have an old 1996 engine from a Citroen ZX 1.9td estate which had intercoolere - we will try to use that turbo.

However - the owner gave us a bare engine and head which he says cost him £300 and he saw it running.

Now we have 3 engines - we know the ZX one is good - we have been assured that the spare boxer one is good - and we cant tell if the one in the van is good because it might be the turbo causing all the problems.

Are the van engines lower compression than the car engines ?

Intercooler aside, is there any chance the ZX engine has more power ?

We are tempted to do the head gasket and valve seals on our ZX engine and fit that - any suggestions.

Also , it would be a quick fix to just fit a turbo to the existing engine, but as the clutch is also crap we are going to take it out anyway.

Thanks in advance.

[CitroJim]

It could be the turbo as black smoke is caused by a lack of air but there's a myriad of other things to check first.

It could be as simple as a blocked air filter.

Check all the turbo piping for security. Check it's not collapsed so that as the turbo is working the feed piping is being sucked flat and causing a severe restriction. Check all hoses and pipes are not holed and are connected tightly to where they should. If an intercooler was fitted it would be necessary to check it for holes.

Can you har any air leaks as the engine revs to signify a severe boost leak?

Two types of turbo were fitted to the XUD, a Garrett and an KKK. They are interchangeable as a complete unit but note that the oil feed pipes are different and will need to be swapped with the turbo...

Any 1.9TD engine will transplant generally in place of another but I'd resist the temptation until you have diagnosed the problem.

Check the turbo is not seized by pulling off the intake pipe to expose the impeller. Try gently turning it with your fingertip. It should spin very freely.

[xsaras4ever]

Great reply CitroJim.

Its sleeves rolled up here then - will keep you posted.

Thanks again

[spider]

I really like these units as there's no complex electronic turbo wastegate or horrors , its all relatively simple.

The air intake is an excellent point, I had one that was smoking once, I found a rag jammed in it ( ! ) from the owners previous DIY that they forgot to mention.

[Dommo]

I've seen a mates 306 TD whose engine had no guts and pouring smoke, believe it or not the problem he had was a clogged catalyst. I wasn't aware they made any 1.9 Turbo D's without an intercooler. Is that what the SD engine was Jim?

It's definitely worth checking that there aren't any intake leaks. Does the van feel like it is struggling for power? If not it could also be that one of the previous owners decided to fiddle with the fuel pump settings without altering the turbo boost pressure which will make it over fuel badly, but still pull fairly well.

[CitroJim]

I've seen a mates 306 TD whose engine had no guts and pouring smoke, believe it or not the problem he had was a clogged catalyst. I wasn't aware they made any 1.9 Turbo D's without an intercooler. Is that what the SD engine was Jim?

I've seen a 306TD with a clogged catalyst too Dom. It was so clogged there was no smoke from the tailpipe at all, just from around the manifold to cat joint. That was a totally and utterly clogged one though... The performance was rubbish and the engine would barely rev... It followed a failed head gasket that cooked the engine beyond repair.

I can see how a partially clogged one could smoke like crazy though... If that is it then the smoke should reduce a little if the vehicle is given an 'Italian Tune-up' which should burn a little of the clogging away.. You might even see sparks and glowing cinders out of the exhaust tailpipe... A badly carbonised back box can do the same if clogged with soot and that can happen if the vehicle is driven very gently for an extended time. Again, an Italian Tune-up will resolve it, complete with glowing clinkers...

The SD Dom was a low pressure turbo. Very little boost and no intercooler.. The 205STDT 1.7TD had no intercooler either but ran a respectable amount of boost and went like the old proverbial scalded cat...

[citroenxm]

The SD Dom was a low pressure turbo. Very little boost and no intercooler.. The 205STDT 1.7TD had no intercooler either but ran a respectable amount of boost and went like the old proverbial scalded cat...

The 1.7 XUD (WELL, its really 1.8, 1769cc's ) was in the 205 and 309s minus an intercooler, they put out 80bhp! When they were fitted to BXs and 405s with an intercooler that was upped to an mighty 92bhp.

[spider]

I've seen a mates 306 TD whose engine had no guts and pouring smoke, believe it or not the problem he had was a clogg The 205STDT 1.7TD had no intercooler either but ran a respectable amount of boost and went like the old proverbial scalded cat...

I can concur I thought about an intercooler but people suggested that as well as the mankyfold change an auto bulge bonnet was needed, then I thought about that but there's no 'guides' on the underneath of the 205 bonnet to channel air to it, so it would not do that much good, a front mounted one is messy too on these.

To be brutal it was extremely lively when it was stock and just set up correctly. I never bothered to turn the overfueling device or the trans pressure up on mine as once it was set properly it was brilliant as is. More so being a 'boring' looking 5 door model as people expected it to be very slow

[xsaras4ever]

Hello to you all again from Bretagne, France.

A big thank you for all the advice on this issue.

Firstly, dah - it has an intercooler. We just expected it to be on top of the engine like in the cars, but it was tucked down beside the radiator, just like in a Landrover.

Anyway, we bought the van very cheap and believe us, vans in France really hold their value.

This is originally a UK RHD van, but it is now on French plates.

We havn't worked on a UK spec vehicle for about 8 years, and had forgotten how things can rust - even all the jubilee clips.
We have been rather spoilt by the LHD French cars.

Anyway, the previous owner mentioned something about the immobiliser and pointed to an extra switch on the dashboard which he said wasn't man enough for the job and could burn out. It is connected to the starter solenoid as a feed and then onto the diesel pump in two places, both of which look like diesel stop solenoids.

We have bitten the bullet and started to remove the engine. It wouldn't run, was coated in oil - really filthy - and we thought with the engine out, we could clean up the engine bay , inspect and clean all pipes and also make a decent decision of which of the 3 engines we would use. We also thought we would do the head gasket and valve-stem oilseals at the same time and therefore buy ourselves hopefully a few extra years with the motor. Also, as the clutch needed doing it was an opportunity to do many jobs at once.

Thats it for now - will keep you all posted.

[CitroJim]

Do keep us informed of what happens with this one...

[xsaras4ever]

In progress removing engine.

Intercooler is not full of oil.

The front on the engine is coated with oil, mostly over near the starter. We discovered when we have taken off the front panel and rads that this is coming from the breather pipe which is pi**ing oil all down the engine block.

The turbo impeller turns freely.

Found usual rot under the battery, so pleased with the decision to remove engine as it gives us a chance to do some welding and painting.

Will keep you posted.

Thanks again to all.

[xsaras4ever]

Here is a photo of the turbo. It is a KKK K14.

The impellor on the turbo turns nicely, and has no play.

Whats the story with the wastegate on these - we are not familiar with them.



Here is a picture of the van at the moment. Not sure we will remember how to put everything back together !!!!

[CitroJim]

Wastegate (and turbo + exhaust manifold) is of a sort I've never seen before on an XUD...

The EGR valve looks odd too. As if it's stuck wide open or has been gutted...

[ekjdm14]

Yeh you're right I can't see a return spring on that EGR now you mention it! Wonder if that was at least part of the issue, failed/bodged EGR letting all the boost escape back through the exhaust causing low power & overfuelling?

Also got to admit I've never seen a wastegate/actuator like that in my life, looks rather cumbersome/messy to me.

[CitroJim]

Yeh you're right I can't see a return spring on that EGR now you mention it! Wonder if that was at least part of the issue, failed/bodged EGR letting all the boost escape back through the exhaust causing low power & overfuelling?

I think it stands a good chance of being a prime suspect! It could certainly give rise to the issues it has...