Peugeot Boxer 1.9d Problem

[CitroJim]

I love that 'tink' sound the locking pin makes on the flywheel when it goes home

All that is good stuff but there's just one thing... Are you using the two locking bolts on the pump sprocket? I'm sure I'm teaching you to suck eggs but the pump sprocket has two index holes and both should be used... There's two so that the pump can, in theory, be removed without disturbing the timing belt. Using two bolts in the two index holes and threaded into the pump cradle allows the sprocket to hang in place with belt still attached when the pump is removed...

Now, if using only one bolt to lock the sprocket may cause the pump timing to end up wrong if the hole you use goes into the wrong one on the cradle...

My apologies if you are already aware of this potential pitfall...

All the very best for success this weekend

[Bolt34]

Now that may just be gold info Jim..
Now I’m excited!
Thank you.
I can hopefully give it a go tomorrow..
Do you turn tensioner clockwise or anti..?? Just to double check

[CitroJim]

Do you turn tensioner clockwise or anti..?? Just to double check

It's spring-loaded so with the tensioner assembly pivot and pinch (locking) bolts slightly loose the ( significant) spring pressure will correctly tension the belt. Once the spring has sprung and done its job tighten the pinch and pivot up moderately tightly and the job's a good 'un...

[Bolt34]

Different to mine then.. I have a Oscillating tensioner that requires a square drive or a Nicely adapted 8mm Allen key to apply the pressure to the belt and do up a 13mm pinch bolt..
I can be turned in both directions to apply pressure..

[MattBLancs]

No, it shouldn't move once torqued. As I understand it, it's more of a belt tensioning thing.

yes you are absolutely correct. Alternatively seen on 16 valve engines (e.g. some EW10J4 engines) it's camshaft pulley that is floating instead. Not normally a Woodruff key in an oversized slot in that application - two part pulley instead. 3x M8? Bolts lock the two together after belt is tensioned.

In either case it allows pulley to rotate slightly whilst belt is being tensioner = even tension either side of the floating pulley.

Yeah Friday!!
A bit of time to try yet again..
Going to check every thing once again but want you all to make sure I’m doing it right for about the15th time..
Timing up again..
Got a lovely Allen headed threaded bolt with a shoulder which fits cam pulley to perfection and screws in snug..
7mm Allen key eased up under the starter motor locates through bell housing and you can hear a ting from the flywheel as it locates..
The back end of a 6mm drill bit fits tight through the fuel pump pulley back plate and locates into fuel pump body..
Leaving the pulley free to move with all 3 bolts loosened..
Where should the pulley sit on the 3 loosened bolts???
I have always made sure it’s central in the bolt slots.. ??
Sorry for boring you all again with my problems..
but just the couple of above questions for now if that’s ok
Btw thank you all for your input..

Interesting, I had a (1995) XUD9TE 1.9 turbo diesel in a 306 Sedan years back, had the best timing pins I've ever come across= bog standard 8mm bolts and better yet engaged into threaded M8 holes in the head / injection pump bracket. Screw them into place and you know timing is sorted.

Disappointing news if that had been abandoned on the DW8 (basically an updated XUD) !!

I'll have a look in a couple of Haynes, I'm sure the pump alignment procedure is described in one of them (might be XUD though)

I'd be seeking to get it timed up the proper method (dial indicator on I think a pin fitting through a hole behind a bolt on end of the injection pump) as would be good to rule this out.

Matt

[Bolt34]

That may be a great help Matt
Thanks..
When I manage to get on with it I’ll let you know if mine has the same..
cheers.

[MattBLancs]

Different to mine then.. I have a Oscillating tensioner that requires a square drive or a Nicely adapted 8mm Allen key to apply the pressure to the belt and do up a 13mm pinch bolt..
I can be turned in both directions to apply pressure..

Piece of door handle rod does the job well too

[doggone1]

Not got it sorted yet taking a break all times ok ok yet again so am really at a loss now

[CitroJim]

Piece of door handle rod does the job well too

Now there's a good tip! I made one years ago by grinding down a spare short 3/8" socket set extension bar and grinding flats on the other end to allow a tight-fitting spanner to be applied to rotate it...

Not got it sorted yet taking a break all times ok ok yet again so am really at a loss now

A break is a good plan in a case like this... Likelihood is you'll come back to it fresh and well-rested and solve it in the space of a few minutes

[doggone1]

Big thumbs up for all your help if it gets sorted I will definitely post the answer

[MattBLancs]

I'll have a look in a couple of Haynes, I'm sure the pump alignment procedure is described in one of them (might be XUD though)

Checked the 206 manual (3757) and that doesn't cover it. Interestingly makes no reference to marking position of pump on its bracket when removing.

I've got a few other DW8 / XUD covering Haynes manuals (3073, 3982, 1922), I'm sure I read it somewhere! Will look in the morning (with refreshed brain/eyes)


As others have said, a break from it does you good

Matt

[Bolt34]

My van run the best it’s ever run this afternoon.. don’t know how though,
Ran like a road roller earlier 35mph chugging and lots of black smoke then white/blue smoke, but yet again get her warm or some other wizardry and she runs so responsive, smooth and quiet!!
(Like I hoped it should as that all remains of original engine is pistons shafts and block)
May leave the timing for now and try and think what’s not working when cold..
Do the ECUs go bad at all??
Can a advance solenoid sound ok (ticking) even if it’s failing??

[Bolt34]

doggone1,
Can you run your van on tick over till she’s hot??

[moizeau]

Bolt, have you got access to a good diagnostic kit that can do actuator tests? My 1.6 HDI 16v used to run rough, spew white smoke and stink of unburnt diesel when I got it. In my case it was the egr. If you haven't, maybe someone with a DW8 could confirm whether the EGR does a 'self clean' cycle when the engine is turned off. If so you'll hear it clicking.

[Bolt34]

Thanks moizeau. Still waiting on my local to slot me in for a cold start diag session..
I have replaced the egr valve with a new one.. the only piece I haven’t changed on the start cycle is the advance solenoid.. that’s why I asked if they can sound good but be duff..??