Still black smoke and reduced power.

One interesting thing is the "hesitation" in normal driving. It's like taking my foot off the accelerator then putting it back on, or driving into a gusty headwind.

Just going along at 40-50, this happens quite frequently. What seems to be a momentary loss of what power there is, briefly.


Considering this on its own, any ideas?

It occurs to me that attaching a pressure gauge to the intake side might be interesting. Unfortunately, from the old days I have only a vacuum gauge, and some positive pressure gauges reading in PSI - i.e. tyre pressure gauges.

Would putting on a pressure gauge be useful?

Fuel lines/Filter?

Black smoke is a sign of ineffective combustion due to lack of air supply to cylinders.
Either the turbo is not working properly or there is an air leak between the turbo and the inlet manifold. I've had both these problems in the past, separately.
First job is check boost pressure to inlet manifold.
A diagnostic tool that shows live data might show the value from the inlet pressure sensor. There is also a pressure gauge adaptor that allows a mechanical gauge to be fitted where the rubber hose connects to the inlet manifold.

Hi Bill (anyone), is it possible for me to get one of these diagnostic tools, or is it a specialist (FIAT?) garage job?

I'm going to do some careful poking around and see what I can see looking at the pipes and intercooler. It's hard for me to get under the van though. I suppose I could park up on the kerb at a bus stop... I should be looking for splits, loose joints, oil mist marks I have read somewhere.

Re: 2.0JTD SX 04 turbo issue (more) (fixed).

Right. Having had the van into the garage, and them fixing a leak in the turbo pipe where a thin pipe tees into the thick one that you can see under where the battery is, and saying it was fixed, and then having it in again and them clearing out all the soot from the cat, and saying it was fixed, and in neither case was it fixed, I poked about and found a long split along and at the top area of a fat 90 degree bend pipe central just behind the radiator just above the bumper that I could put my thumb into.

So I had the pipe off (two pipe clips). It was a bit oily inside and a few drops of oil leaked out. There was a bit of oil sprayed up the bottom front of the engine. The 90 degree rubber bend joins two black plastic pipes one coming from the back of the engine (turbo?) the other going to the left hand end of the intercooler as you look from the front under the bonnet.

The pipe was cleaned up with a bit of white spirit on absorbent paper, and the split bit taped up with several layers of Lidl's duct tape torn into long 1" wide strips, taking care to compress the rubber hose to retain the pressure but only slightly so it didn't get too small and not go back on again, and to keep the sticky tape clean so it actually stuck.

Off to see someone in hospital, late, so I dared put my foot down. Zoom! Blatt! Performance restored, you know how these vans shift, well this one does again. Booting it at the lights resulted in someone who'd been tailgating dropping back 'cos he could not see where he was going - ! I have never seen so much black "stuff" blasted out of an exhaust pipe before! The soot now seems to've cleared.

So, it's done 30 miles on a taped-up bit o' pipe. It's good and I am having a couple of pints and thinking about where to get a new hose tomorrow.

My problem was thinkling the garage knew what they were doing, and worrying that the whole thing was too difficult and I'd never see a little split in a pipe on a complicated engine with lots of pipes all over the place - but it was easily seen from above, using a torch!

Cheers!

Great you got it fixed temporarily. The oil will eventually get the tape loose so get a hose. That hose is expensive because a new one comes attached to the plastic bit. Look on eBay, but make sure you get the right one.

The diagramme helpfully uploaded by Andycabs does not seem to show the hose I've got. The failed part is a short 90 degree rubber bend between two straight hard plastic hoses, held on by a clip at each end. I will phone around.

Can't see one on eBay at all.

Can't find part on eBay or ePER ("heat exchenger"?).

It's this bit:

http://bit.ly/1LY3DRx

first pic, the rubber elbow in the middle. Don't think I want to get it from Sweden...

Hen's teeth. Absolute hen's teeth.

OW! OW! OW!

[FONT=&quot]"no.3 in the image is priced at £150.72+vat. A special order item[/FONT]"

Expensive like I said. A couple of years ago when that hose popped on my Scudo there was somebody on eBay selling a non oem replacement. Looks like he's not listing them anymore. This was the eBay item number 161062279904.
The same hose is used on other Peugeot/Citroen vehicles.

Tape lasted 1,400 miles, buzz then loud whistle indicated failure!

Trying to get one of these made from silicone rubber/polyester. Any interest?

OTOH would this fit, perhaps?

http://turbo-hose.com/0382.HQ-PEUGEOT-TURBO-HOSE

Replacing the elbow from the turbo, the pipe that runs on top of the crossmember, and the elbow into the intercooler.

Zog said:

OTOH would this fit, perhaps?

http://turbo-hose.com/0382.HQ-PEUGEOT-TURBO-HOSE

Replacing the elbow from the turbo, the pipe that runs on top of the crossmember, and the elbow into the intercooler.

Click to expand...

at @£20 it's got to be worth a punt..

you could always slice it into yours - cutting out the rotten bit..!!,

Charlie

Also here:

http://www.ebay.co.uk/itm/CITROEN-J...O-INTERCOOLER-HOSE-PIPE-0382-HQ-/171380835972

1. Car:
   • Citroen C8, Production year: 2000-2014
     Engine: 2,0 HDi
   • Citroen Jumpy, Production year: 2000-2006
     Engine: 2,0 HDi
   • Fiat Scudo, Production year: 2000-2006
     Engine: 2,0 JTD
   • Fiat Ulysse, Production year: 2000-2006
     Engine: 2,0 JTD
   • Peugeot 806, Production year: 1999-2002
     Engine: 2,0 HDi
   • Peugeot Expert, Production year: 1999-2006
     Engine: 2,0 HDi

Re: 2.0JTD SX 04 turbo issue (fixed)

Bought the hose from turbo-hose.com (Google: turbo hose 0382.HQ for various vendors).

It fitted, replacing the burst elbow (just above/behind the front bumper, in the middle), and the glassfibre/plastic pipe, and the elbow to the intercooler.

The volume of the pipe has increased (compared to the original). I hope this won't affect anything, but if it does I'll cut off the part requitrd to replace the elbow & use that.

An easy job.

Thanks Zog,
I have had a loud whooshing noise appear and loss of power. Just about given up and was ready to book in to my mechanic, when I read your threads.
The pipe you replaced had come off the intercooler!!
A couple of minutes and it was back on and van is back in beast mode.
Thank you for your detailed descriptions, saved me big time.

Coo! It's what the forum's for, IMO. Looking back, it seems my comments were rather on the spur of the moment, and confused/confusing. I'm very glad you managed to make something of it!