Peugeot Boxer 1.9d Problem

[doggone1]

Hi all I have a 1999 1.9d non turbo Peugeot Boxer Camper it broke down and had to be recovered since then it has been to two garages and still not sorted so I’m having to try myself story so far only revs to 2750 rpm and blows white smoke and lumpy it starts and idles perfect the Garage fitted new glow plugs injectors and pump sent away and rebuilt so far I’ve compression tested it 400 to 420 psi on all cylinders cam belt was done at first garage injectors at second neither changed fuel filter so I’ve done that I got the injectors retested no leaks pop of at about 2000 psi checked timing and all pins up as it should running with air box of at the moment egr disconnected tested and working seems like a timing issue but all seems ok could it be 180 out? But would it start so well if it was could anything be out on flywheel pulley or pump pulley etc it’s got me stumped now any ideas I’ve checked fuel and seems good even run it on fresh diesel on an auxiliary tank still the same seems like timing but it all pins up that’s what I can’t understand any hep greatly appreciated

[moizeau]

Is the injection pump timed? Not talking about the locking pins on the sprocket, the actual pump can be moved a few degrees in either direction on it's mounting bolts. Mark where the pump is with a scribe, slacken the bolts very slightly then rotate the pump by a couple of mm in both directions to see if it improves. There is a correct method to set it using a DTI (I'm sure Citro Jim posted it a while ago) have a search through the forum. But moving the pump a little will tell you whether it is in fact the issue.

[doggone1]

I tried turning it all the way forward and it made it a bit more noisy rotated it all the way to the rear slight improvement but still won’t rev past 2750 and smokes white smells of diesel

[RichardW]

If it suddenly happened then something broke. If the injectors are OK, and the compression looks OK / even, then finger has to point at the injection pump....

[doggone1]

The pump was sent of and tested it was ok apparently but was refurbed any way £400 later I’m hoping it’s not the problem when I was recovered they got it to start pumping the primer bulb first garage replaced the fuel solenoid on the pump I believe would it pay to connect some clear tube on the return line to check for air bubbles clutching at straws really

[RichardW]

Missed the bit about the pump refurb...I think I would take the belt off again, and the sprockets, and check that the wood ruff keys were present, and that the position of the sprockets actually matches the cam / crank! Although you've got apparently good compression it does appear that the timing is out somewhere.

[doggone1]

I think that’s my only option I was racking my brains where to go next till I do as you say I’ll never know for sure I’ll keep you posted when I get it checked thanks for your reply

[doggone1]

Managed to have a look at it today I’ve taken a pic of the camshaft with the flywheel pinned and pump and cam locked I think no1 cylinder is flywheel end this appears to be on the rock with it timed and cylinder camshaft end appears to be on compression I’ve attached a pic do you think it looks correct

[Bolt34]

Hi all, did anyone come up with a solution to your timing issues..??
I’m asking cause I have a expert van running a DW8 and I have some of the same issue’s..
New refurb to pump new injectors, cambelt and egr valve..
I can move the pulley on the fuel pump and make it run fine hot or cold but not both??
So puzzled???
Any info gratefully received..
If I come up with a solution I will post on here and on Peugeot forum as I have read a few stories like this but, none of them resolved..

[CitroJim]

I can move the pulley on the fuel pump and make it run fine hot or cold but not both??

Sounds like a problem with the cold start advance mechanism... If my memory serves me correctly - and it's been a long time now since I've played with one but you may find a large solenoid on the side of the injection pump that applies a degree of extra advance to assist cold running. This should deactivate once the coolant is nice and hot...

A voltmeter looking at the feed to it should show if this is operating as it should...

[Bolt34]

Hi CitroJim, thanks for your reply..
I have tested feed to solenoid and all is good it ticks away nicely with ignition turned on.. I’ve taken it out of the pump and run12v through it and it seems to be spitting fuel out through the wire gauze, so presuming its working fine..
I have also tested continuity from pump, advance solenoid and lift sensor back to ecu plug all fine there too..
I got a reading of 114ohms from the lift sensor.. is that ok do you know?? I have read it should be between 90-100ohms, does that make mine faulty??
Any come back appreciated..

[CitroJim]

That resistance reading would suggest to me the Lift Sensor is good. They normally fail open-circuit..

The cold advance solenoid would appear to be good too...

I'll have to think harder

[Bolt34]

Ok mate thank you..
Would MAF make much difference to starting/ running as I can in plug it when running and there is no difference to how the engine runs?? Can they be tested??
Many thanks

[CitroJim]

Generally, a MAF can only really be tested by substitution with a known good one...

If it makes no difference plugged in or out it's worth trying another one...

I believe they can be cleaned - with great care and using the right solvents - but often, as I understand it, they sometimes don't stay good for long after cleaning and are easily damaged in the process... Worth doing to see if it makes any difference, even for just a short while...

[moizeau]

I this a DW8? Does it have a wax stat? Only played with real Xud's