Expert 2011 1.6hdi No Boost

[Bikerbutch]

Hi people I’m hoping someone can help me with a problem that’s been plaguing me since march!!

Bought van as its an old wheelchair adapted vehicle and converted to a basic camper to do festivals in - perfect

Bought it off an old woman, trusted her, paid her, when I got there it’s in limp mode and all of a sudden she can’t be contacted. So I drove it home 300 miles, apart from limp mode it drove faultless. Just slow.

So I got it home and took it to my local service centre that does my MOTs gave them the sob story and they said they’d look.

The identified MAP/MAF sensor issue and EGR.

They replaced both. No different. They said as it held at 3k revs even going down hill they suspected the ECU had been played with and flashed. They were at a loss. They felt so bad they only charged me for parts. Fair enough.

So I searched for a mapping company near me, took it to them, he refreshed to a standard map, and upon testing the vacuum solenoid wasn’t vibrating or making any noise so he replaced this. He confirmed it had been messed with and the ECU map had been password protected but put a standard map on it and he recoded the injectors as a part of that.

He somehow got it out of limp mode so it will freely rev now, but still no boost. It’ll do motorway speeds, eventually, but come a hill it struggles massively.

He had an electrician look over it and was at a loss.

I’m an old school diesel fitter I’m s**t with electrics but I bought Lexia and I replaced the turbo with an eBay one as I suspected a waste gate fault, it rattled. There was tons of soot in the CAT and when I squirted cleaner down it, with a rubber glove over the end it was inflating so the flow was restricted, so I replaced that too for good measure.

The turbo is getting vacuum and pulling the arm across but won’t boost above 1100mpa so it’s boosting a tiny tiny bit.

The only difference in all of this is:
After replacement of turbo I actually got a P0299 code which I didn’t

On Lexia some of the egr values were coming up with invalid value, so I put a blanking plate on just for diagnostic purposes. Now getting a code for that. But Again no different.

Took it for a long drive to the lakes, no boost. Just as ann idea Unplugged the MAF/MAP sensor on the intake, only difference is much more smoke at start up, no boost still.

I have never had an engine light on it yet!

I’m truly at a loss. I’m using it as it is, but it would be more pleasant to drive with a bit of boost for slip roads and hills.

Any help appreciated

It’s the 2011 1.6hdi 90bhp version

So to be clear in conclusion.

Bought in limp mode no boost wouldn’t rev above 3k
New map/maf
New EGR
Reflashed ecu to standard
New vacuum solenoid
New turbo
New CAT

Still no boost

Anyone any ideas?

[mickthemaverick]

I don't know the engine very well myself but seeing the things you have already done I would suggest that maybe you have a blocked intercooler/induction pipe somewhere which is limiting the boost. Hopefully Citrojim will see this thread and probably be able to advise you more expertly than I.

[Bikerbutch]

Thanks for this. I’ve checked all plumbing up to the intake manifold. Intercooler is clear, the boost I’m sure is being limited, as there’s no boost noise- that’s my gut feeling.

[mickthemaverick]

I think you might find a read through this thread on the Peugeot Forum will give you a couple of things to check: https://www.peugeotforums.com/threads/i ... 99.191546/

[Bikerbutch]

Thank you, yeah I read through that. I don’t have a bov or diver yet than I can see I think everything is controlled by the vacuum electrosolenoid

Very frustrating

[RichardW]

If you look in live data what does it say the reference boost pressure is vs the actual? What about the output to the boost solenoid?

I can't remember if vacuum = boost or the other way around, but you could try connecting a mitivac to the turbo and then applying some vac to it to see if it starts to develop some boost.

[Bikerbutch]

The reference boost is higher than the actual, I think that’s why I’m getting the p0299.

Now I’ve just been out playing with it. It’s very odd.

With the engine off, there remains vacuum at the turbo, a lot, if I pull the vac pipe off, it doesn’t suddenly lose vacuum it stays ‘sucking’ for a while until it eventually runs out.

Now then, do that, and put it back on and take it round the block. No vacuum. Very strange. I’m beginning to think it’s pipework and vacuum solenoid (which he replaced he said) - can’t get to it without ramps so going to have to get some ramps and crawl under to see if I can locate it and check all the pipe work I think - unless someone else has any ideas.

I’ve squirted some brake cleaner down it then some wd40 just incase it’s moisture doing it, never know you’re luck, and I’ll take it down the dual carriageway later with live data on again.

It’s a shame there’s no vacuum live data.

[RichardW]

There's a vac reservoir on the back of the engine under the starter. The boost solenoid is down the back of the engine, driver's side. Easy to check for gross vacuum as it also runs the brake servo, so if you deplete that engine off, then press the brake and start the engine and it should go down some as the vac builds in the system.

[Bikerbutch]

I’m beginning to wonder if it’s possible the pipes are on the vacuum solenoid the wrong way. When you turn the engine off the turbo actuator gets pulled across.

Or an issue with the piping. Like collapsed pipe or a failed one way valve or something.

Next step is getting under the bloody thing.

[RichardW]

With no vac the turbo actuator should be up, and you should be able to press it down quite easily; once engine is started vac should pull it down - at least that's what it does on a 110 - the early 90s had a waste gate turbo rather than a variable vane, so may have worked differently.

[Bikerbutch]

Well as an update. I’ve finally got to the bottom of it!

The vac solenoid was the wrong one. Looks like someone else had been having a go at this.

So put the right one on, and still the same so checked all the pipe work. And I was dumbstruck.

4 mechanics, the previous owner, all missed a blocked vac pipe to the turbo. I put a bit of washer tube on it I had to hand to confirm diagnosis. Drives spot on, full boost, no underboost fault code. Top banana!

New silicone vac pipe ordered, new valve already on it.

Polish it off this weekend.

So relieved. (With undertones of annoyance mechanics had missed something so simple and put the wrong vac solenoid valve on it without checking the right part no)

[mickthemaverick]

Good to know but I thought I suggested you checked all the pipes right back at the start of the thread?

[Bikerbutch]

Yep, I’m guilty of not checking it thoroughly. I had presumed the people before me would have picked up on it.

I blew down it one way only. And it had collapsed in a way that it was letting vacuum through but not when released.

The old bloke I did my apprenticeship with back in the 90s was in the back of my head going, check the basics knobhead