Peugeot Partner Combi Mk1, 2001, 1.9d WJY
Vehicle background:
Bought in November, working but leaking head gasket, drove fine but needed coolant topping up regularly. 190K+ miles though 70K in the last three years which could indicate replacement BSI/instrument cluster previously. Found the coolant level sensor gunked up and disconnected
Works done:
Head gasket, water pump, pulleys, tensioners, radiator, timing belt, aux belt all replaced, coolant sensor cleaned checked and reconnected, though the O-ring isn't sealing well so some leakage over the connection. Noticed the lower EGR valve vacuum hose connection snapped, attempted to reconnect with superglue but with obvious consequences, so will disconnect EGR vacuum hoses and plug them to disable EGR. I did find the engine end of the EGR pipe was slightly loose but have been able to repair with careful application of exhaust sealant. Noticed the battery holder to be detached from the chassis so added a couple of bolts, so might have been replaced previously along with the engine ECU
Result:
Van starts well, no leaks, no stutters, drives well but the instrument cluster has stopped working - no rev counter, speedo, fuel level, indicator indicators, LCD feed, etc but the warning lights are working correctly such as oil and airbag
Diagnoses:
Read with Lexia/PP2000 due to it being so old it needs PP2000 and have permanent faults in BSI for VAN data wire and VAN data BAR communication failures, along with engine ECU reference and inability to read engine ECU faults, no communication with the radio ECU though the radio functions perfectly and I was able to remove the tape, a Cat Stevens' compilation. So far I've disconnected the instrument panel, attempted to gain access to its innards but it is firmly encapsulated with the various clips and pins, not having a printed circuit film but rather a solid board firmly attached to the needles which I don't want to break. The radio has been disconnected to determine if there is interference on the VAN from that. BSI removed and in doing so I've noticed two very cleanly cut wires at the location of the circular connection in the footwell behind the BSI which don't appear to have been disconnected at any point, they're just not connected - one beige and one white wire. The BSI is bone dry, as are the earth points in the driver's footwell and both the inner wings at the front of the bonnet. I've checked all fuses are OK and reconnected them all. There is no sign of water ingress or corrosion I can identify. I've yet to unpack the multimeter but the car hasn't moved since disconnecting the battery a month ago and has been sheltered.
Questions:
- With the current price of a second hand instrument cluster for this van (two connections - white and black) being rare and as expensive as a repair by BBA-Reman, the works that have been done, the reasonably good condition of the vehicle and the history, is there something more obvious that I'm missing to fix the instrument panel problem?
- I've sunk a good £200 into it getting it back to good running order with only the instrument panel being the problem, so without any more investment is there more I can do to fix the problem without taking the wrong pill?
- Could a leak onto the coolant level sensor connection cause problems on the VAN bus?
- Could the engine ECU have been replaced without a matching BSI by using the original ECU to trick the BSI into accepting the different ECU? If so, how do I fix this without having the original ECU?
- If the VIN for the radio/instrument panel/engine ECU/BSI doesn't match at any point, would this cause the BSI to disable communication with the other components?
- Is there a simple way to diagnose a faulty instrument cluster?
- Is there an easy way to check the BSI matches ECU & Instrument cluster?
- Errm..... help?