As the saying goes "sleep on it".. So in the morning I woke up knowing exactly what I had to do. Jump under the van and managed to remove stubborn bolt one the bottom bracket. Attacked it with a nut splitter & chisel, got it loose and got the mole grips on it and ratchet spanner. Up a good fight till the end. That left the last M8 nut pls manifold stud with a bracket to the turbo. It was obstructing the last nut between the turbo and the exhaust manifold.
Found my pry bars and bent it off. Seized bolt on other end of bracket on turbo then became loose, but only after I bent the bracket. Phew got that off.
Then unscrewed the finial stud in the manifold. Had to make a locking nut using two nuts to get the stud out. After its was the only stud that did not unscrew while I was taking the exhaust manifold nuts out. Left the two nuts on the cam side of the manifold as I could not see them or work out what they where. so managed to us an Allen key to remove the clamp at the other end of the pipe.
Pulled it all out and cracked the two M10 nuts off the tube.
Then cracked the last turbo job done.
Now I'm at the apex of this job...
Bust the following tools
M11 spanner
M13 spanner
M13 ratchet spanner
3/8 ratchet
Small Laser nut splitter
Went down to Halfords and found a new laser nut splitter to replace the I bust as U was half way though the job. Paid £14. but they did not have any chisel's. So pop into tool station to get a chisel and guess what they had a twin set for £6 so I got the chisel and the nut splitter set and took the laser nut splitter back to Halfords saved £3 wow cool hay lol..

At the minute I've been sorting parts out.
Turbo manifolds bolt only from dealer *4
(£2 + vat each!!! bargain)
Oil seal Washers *4
Plus an inline filter for the oil.
Paid £16 for that lot
Dropped turbos off at Turbo Technics in Northampton.
They said "61" k03 433504 off van had a seized gate valve and 62 k0364732 was worn out. but it was working ok on a van before I got it?
Did have oil dripping out of it so think it need new seals tops...
I will be getting 61 repaired at a cost of £250 + vat they will give me £90 for the old unit. so should cost me £234.
I also pulled the heat shield off the EGR valve pipes, Half my "Tool Spring Terry Clips" are rusted to death, luckily I've got a heat shield spare, so drill the the clips out and made one good set out the the two.
I was looking for 25mm or 1inch Terry Clips hopefully in stainless steel.
Screw fix do the zine plated ones for a few quid. but for now I've got a repaired one . They also look nice polished lol.
Replacing all the exhaust manifold bolts and have replace some of the studs that where rusty. My manifold spacers where really rusty so have de rusted them and painted them in heat resistance paint. Will look good for ten minutes when I reassemble. Resisted the temptation to, do the manifold and the bit on the turbo, as I do not have a blast cabinet at the minute. Have done this in the past, as I really hate rust...
Managed to order new manifold gasket after lots of fuss with reg number chassis number etc, still really struggled ? I have ordered new turbo gaskets so I will be fitting a gasket between the manifold and the turbo. I did not see one on the van and not sure about sealants etc so like the gasket option.
Not sure if a seized gate valve would pressurize the rocker cover.
When sorting the heat shield off the EGR pipe work I noticed how really sooty my shield was. I have a spare EGR valve which looks like new so I will swoop that out aswell , if the EGR cooler is not connected to the coolant system on the vehicle Then I swoop that aswell.

After I assemble all the parts should take a dry day or two to get it all back together. "Famous last words" lol

I've never seen a turbo workshop turn down money so no surprise there. Those turbos are very reliable unless grossly abused, oil on the intake side is just as likely to be from the PCV, if the turbo isn't noisy and theres no play in bearings then clean out the pcv, intake hose and compressor housing and drive it. If oil reappears in the housing and not up by the pcv then think about rebuilding it.

Aftermarket inline oil filter is introducing another failure point into the system.

PCV valve has been stripped and cleaned.
Removed EGR valve tested ok. So I cleaned it. Lots of new parts have turn up. Turbo Monday/Tuesday. So on Saturday I removed the rocker cover and replaced the gasket. One of the bolts was loose, but the oil leak is pretty even all around. Managed to clean the rocker cover, must of had 3mm of sludge round it, in places.


This oil leak is very worrying, so I'm getting a diesel compression testing .


1/4 ratchet is shot now but that's been on the way out for a while now. Getting the hose clips back on was a real pig and the EGR valve rhs clip is such a pig I can't get it back on for the minute. I got a few of the spare. Was really surprised at the cost of them new. In all I used to do this job on the punto and it took 20mins top, I would spend more time looking for my tools. But its a real pig job on this van. Had to take the cam belt top cover off, so managed to inspect the cam belt. It looks 3 to 5 yrs olds so will be swopping it out after the van has passed its MOT.

Chriselectrics said:

PCV valve has been stripped and cleaned.
Removed EGR valve tested ok. So I cleaned it. Lots of new parts have turn up. Turbo Monday/Tuesday. So on Saturday I removed the rocker cover and replaced the gasket. One of the bolts was loose, but the oil leak is pretty even all around. Managed to clean the rocker cover, must of had 3mm of sludge round it, in places.


This oil leak is very worrying, so I'm getting a diesel compression testing .


1/4 ratchet is shot now but that's been on the way out for a while now. Getting the hose clips back on was a real pig and the EGR valve rhs clip is such a pig I can't get it back on for the minute. I got a few of the spare. Was really surprised at the cost of them new. In all I used to do this job on the punto and it took 20mins top, I would spend more time looking for my tools. But its a real pig job on this van. Had to take the cam belt top cover off, so managed to inspect the cam belt. It looks 3 to 5 yrs olds so will be swopping it out after the van has passed its MOT.

Click to expand...

hi. been there done that:bang: jud

syldale said:

hi. been there done that:bang: jud

Click to expand...

How long did this job take you? I have been held up by bad weather, and now waiting on parts...

hi. read this thread https://www.fiatforum.com/ducato/449082-new-clutch.html .jud

Total spend to date £553.67
All this for the 2.0 turbo engine.

Just collected my turbo from turbo Technics. I though I had been txt by them stating £236,but it was not them?
But ended up paying £300 so I got an extra eight exhaust manifold bolts out of them. I only paid up because I known what a good quality job they do. Turbo comes with 12 months warranty.

Total Spend To Date Break down.
Clutch 3 piece £76
Clutch Fork £22.49
Clutch Guide seal £12.99
Reverse switch 4.99
Copper seal for above £2
Hose clamps £5.40
Manifold Flange copper nuts £2 ( still on order)
Exhaust Gasket £6.33
Brass washers £2.99 ( yes I know)
Turbo bits (bolts seals) £16
Cam Cover gasket £7.75
Turbo gaskets £8.75
Turbo charger £300

So up to MOT I would have done the following.
Replaced Reverse switch £45
Cam rocker cover gasket 120 to 180
Clutch 650 to 1250
Turbo 450 to 750

So doing really well ....
I've also had to spend £60 ish on new tools as I only tooled up for petrol engines. Bought compression tester for diesel engines.
I will be spending more on tools when I figure out what size threads the injectors are.As I want to pull them all out and clean/check them out replace the seals etc. I believe Im running BOSH, but just a guess. Could be running either Denso or bosh. But knowing, these guys it could be Siemens Delphi as well, As they really seem to like confusing people when it comes to parts.

FIAT DUCATO 2.0 JTD 2002-2006
BOSCH DIESEL FUEL INJECTOR 0445110076 9641742880
Also found on other vehicles

Peugeot
407 / 406 / 307 / 306 / 206 / 607 / 2002-2006 Boxer/expert (I would think) 2.0 HDi
Citroen
Picasso / Xsara / C5 / Relay

Ford
Alfa
Volvo
Vauxhall

Believe it needs either a 29mm or 25mm
DIESEL INJECTOR PULLER SPROCKET EXTRACTOR REMOVAL TOOL

Nice set on ebay / amazon

Diesel Injector Puller Extractor Remover Peugeot Citroen 2.0 2.2HDI Injectors
by Mekanik
4.2 out of 5 stars 2 customer reviews
Price: £34.99 FREE UK delivery.

Beautiful day today, Oh yer better start fixing that van...
Sorted the messed up 6mm thread and put a new bolt in from last week when I was doing the rocker cover gasket. Assembled the EGR tube on the manifold. Secured it to the EGR valve. Put the exhaust manifold studs in one at time. Put new exhaust manifold gasket on and pushed manifold up. Tighten on nuts one at a time. Then started on the turbo. Installed new need filter. Very important. Will be replacing the engine oil as well. Finally finished at 8pm tonight. I the morning I will start on the clutch.
Been looking at the engine the oil leak, its mainly at the front of the engine.
Just my luck its also on the cam belt sided. Not as bad as the front but still there. Maybe the loose bolt was to blame, in in my experience its never that easy.
I also looked at how you might remove the engine and gearbox.
exhaust, steering pump, electrics, coolant, fuel, engine mounts.
Normally I will lift the lot out, but I don't believe their is enough room.
so you would have to remove the front end or drop the lot?
Not something I want to do at the minute as I need to get this van back on the road so I can get organised, and get my life going in the direct I want.

Monday night put clutch plate and housing on. Removed a few pipes for cleaning. They had an oily sludge poring out of them. Its the pipe that connects the rocker cover to the turbo. The small one with the sensor in it. Not sure how to test this sensor at the minute. They had unplugged this sensor so I think it going to be trouble.
The clutch release bearing only has two very small metal lugs to attach to the clutch fork. Looks like it needs a clip or something. Also the plastic PIVOT BUSH / Knuckle on the clutch fork is rubbish. I assembled it and was unpressed. Its very sloppy and I think I will have to buy a genuine part. The clutch fork is good quality solid part but the bush is a sloppy fit.To the point where I think it may even fall off if pushed too hard.
I will be taking the clutch release bearing and clutch fork down to the parts place to see what they think. I've seen hydraulic clutch release bearing for a 2.0 D so, maybe that would be a better option.

Been waiting on the new clutch release seal guide to turn up. Mine was in pieces so had no idea what it looked like. But hoping that the post man will bring the correct part today and I can crack on with this job.

bank holiday
got the gearbox back on drive shaft in
struggled like hell...
replaced engine oil & filter
flushed gearbox with engine oils to wash any nasty out..
then refilled with gearbox oil.. Gearbox cap is now missing?
Cleaned it put it down and ping ..its gone?


This week end connected turbo pipes up.
took hours..
needed to put rubber on middle of turbo before putting turbo on van.
then hook bottom longer pipe on the put the shorter on one. Otherwise is a world of hurt...
Connected gear linkages up


Stuck with four bolts on the hub.
small bolt under Neath hub.
Replaced the track rod end as I had to cut the nut off the old one.
started. Routing cables into correct positions.

Got Stuck into the four bolts on the hub "lower ball joint".
these bolts hold the lower LOWER BALL JOINT on.
I managed to get it back on then realised that I need to put the splash plate on!
So I took two bolts out and put the plate on. It was a bit fiddly but managed to do it.
Tomorrow night I will do the earth strap on the gearbox and thats it at the lower side. I need to check that the gear selection is working ok. But I believe it should be fine. I will be replacing the big nut at the bottom on the lower ball joint and the nut off the stabiliser link, thats connected to the anti-roll bar. I think the stabiliser link is due for a change away.
Can you get Polyurethane Bushes for these vehicles?

Hi All
Just bought a stabiliser link at the local £12.55
Ebay £11.65 ish


This place was under £6???
http://www.buycarparts.co.uk
I will be checking other parts out.


I normally replace both side. but will do this after the MOT is done.
While I was in the auto factors I noticed a sign about MOTs on diesel engines.
I said that they will ask you if you cam belt has been replaced?
If they do not get the answer they require they will refuse to perform the MOT test.
Surely if they damage the engine during the test, they will be liable?
I use to get this with the series 3 land rover if you took it to the wrong place they would destroy the rear hand brake. Luckily I knew where to take it

FYI

You are not permitted to sign any disclaimer regarding your vehicle and the MOT Test, but with regards your cambelt and its condition the following will apply;

If you advise the reception or the nominated tester when asked about the condition of your cambelt, that it is in a satisfactory condition to have a test carried out, then the nominated tester will carryout some pre-checks, if those checks prove to be satisfactory, then the test will be carried out.

The engine is not put under any load when tested.

If the engine drive belt fails during the test, and the nominated tester could not foresee this event, and having spoken to you advising that the cambelt is in good condition to carryout such an examination, then the only option the tester has if in any doubt is to refuse to test your vehicle, but the Testing Guide says;

An examiner will be liable for the following types of damage in certain circumstances, the type of damage are;

(a) Loss or damage to a vehicle that has been submitted for a test, but the Testing Guide goes further, the advice is;

Examples of damage are intended to cover are where an examiner, whilst testing the vehicle smashes a light, or causes the steering to become defective, or inflicts over types of harm to the vehicle that did not exist at the time it was left within the possession of the garage.

So what is really being said above is that IF the damage is unforseen, then the garage would not be liable. If therefore you believe that the belt could be damage, you have a common law duty to ensure that you have your vehicle maintained to the recommended standards at all times it is used on the road.

An mot test is not a way out of professional maintenance, and the station cannot be blamed if you know there is a likely possibility that a fault could occur.

List of vehicles with the same very similar engine to my van.
I Believe that the DW10UTD 84Bhp is fitted to my van, and the DW10ATED 107Bhp is the uprated version. Its important when you want to change something like the turbo. Or want to fit a stronger timing belt?
You can pay £650 for the DW10UTD turbo. But the Suzuki Grand Vitara (1998->2005) 2.0TD RHZ Diesel, 8 Valves, 107 BHP Turbo can be found for £160 ish on ebay brand new. Needs two manifold studs drilling out, and one removing, which is not the end of the world.

Then you might want to use the Haynes manual as reference so there are lots of cheap Haynes manuals kicking about with these engines.

Make
Model Description L Engine Code Engine Description
Citroen Berlingo Multispace (1998->2002) 2.0HDi RHY (DW10TD) Diesel, 8 Valves, 89 BHP
Citroen Berlingo Multispace (2002->2012) 2.0HDi RHY (DW10TD) Diesel, 8 Valves, 89 BHP
Citroen C5 Mk1 (2001->2004) 2.0HDi RHS (DW10ATED),RHZ (DW10ATED) Diesel, 8 Valves, 107 BHP
Citroen C5 Mk1 (2001->2004) 2.0HDi RHS (DW10ATED),RHZ (DW10ATED) Diesel, 8 Valves, 107 BHP
Citroen C5 Mk1 (2001->2004) 2.0HDi RHY (DW10TD) Diesel, 8 Valves, 89 BHP
Citroen C5 Mk1 (2001->2004) 2.0HDi RHY (DW10TD) Diesel, 8 Valves, 89 BHP
Citroen Synergie (1995->2002) 2.0HDI RHZ (DW10ATED) Diesel, 8 Valves, 110 BHP
Citroen Xantia (1993->2001) 2.0HDi RHZ (DW10ATED) Diesel, 8 Valves, 110 BHP
Citroen Xantia (1993->2001) 2.0HDi RHY (DW10TD) Diesel, 8 Valves, 90 BHP
Citroen Xsara Picasso (2000->2010) 2.0HDi RHY (DW10TD) Diesel, 8 Valves, 90 BHP
Citroen Xsara (1997->2005) 2.0HDi RHZ (DW10ATED) Diesel, 8 Valves, 110 BHP
Citroen Xsara (1997->2005) 2.0HDi RHY (DW10TD) Diesel, 8 Valves, 90 BHP
Citroen Xsara (1997->2005) 2.0HDi RHY (DW10TD) Diesel, 8 Valves, 90 BHP
Citroen LCV Berlingo (1996->2002) 2.0HDi RHY (DW10TD) Diesel, 8 Valves, 90 BHP
Citroen LCV Berlingo (2002->2012) 2.0HDi RHY (DW10TD) Diesel, 8 Valves, 90 BHP
Citroen LCV Dispatch (1996->2007) 2.0HDi RHZ (DW10ATED),RHZ (DW10BTED) Diesel, 8 Valves, 110 BHP
Citroen LCV Dispatch (1996->2007) 2.0HDi RHZ (DW10ATED),RHZ (DW10CTED) Diesel, 8 Valves, 110 BHP
Citroen LCV Dispatch (1996->2007) 2.0HDi RHX,RHX (DW10BTED) Diesel, 8 Valves, 95 BHP
Citroen LCV Relay Mk1 (1994->2002) 2.0HDi DW10TD,DW10UTD Diesel, 8 Valves, 86 BHP
Citroen LCV Relay Mk2 (2002->2006) 2.0HDi DW10TD,DW10UTD Diesel, 8 Valves, 86 BHP
Citroen LCV Xsara Enterprise (2003->2004) 2.0HDi DW10TD,DW10TD/L4 Diesel, 8 Valves, 90 BHP
Fiat Ulysse Mk1 (1995->2003) 2.0JTD RHZ Diesel, 8 Valves, 107 BHP
Fiat LCV Ducato Mk3 (2002->2007) 2.0JTD RHV (DW10) Diesel, 8 Valves, 83 BHP
Fiat LCV Scudo (1996->2007) 2.0JTD RHZ Diesel, 8 Valves, 109 BHP
Fiat LCV Scudo (1996->2007) 2.0JTD RHZ Diesel, 8 Valves, 109 BHP
Fiat LCV Scudo (1996->2007) 2.0JTD RHX Diesel, 8 Valves, 94 BHP
Peugeot 206 (1998->2009) 2.0HDi RHY (DW10TD) Diesel, 8 Valves, 90 BHP
Peugeot 206 (1998->2009) 2.0HDi Eco RHY (DW10TD) Diesel, 8 Valves, 90 BHP
Peugeot 206 (1998->2009) 2.0HDi RHY (DW10TD) Diesel, 8 Valves, 90 BHP
Peugeot 306 Mk2 (1997->2003) 2.0HDi RHY (DW10TD) Diesel, 8 Valves, 89 BHP
Peugeot 307 (2001->2009) 2.0HDi RHS (DW10ATED) Diesel, 8 Valves, 107 BHP
Peugeot 307 (2001->2009) 2.0HDi RHS (DW10ATED) Diesel, 8 Valves, 107 BHP
Peugeot 307 (2001->2009) 2.0HDi RHY (DW10TD) Diesel, 8 Valves, 89 BHP
Peugeot 307 (2001->2009) 2.0HDi RHY (DW10TD) Diesel, 8 Valves, 89 BHP
Peugeot 307 SW (2001->2009) 2.0HDi RHS (DW10ATED) Diesel, 8 Valves, 110 BHP
Peugeot 307 SW (2001->2009) 2.0HDi RHY (DW10TD) Diesel, 8 Valves, 90 BHP
Peugeot 406 Mk1 (1996->1999) 2.0HDi DW10ATED,DW10ATEDL3,RHZ (DW10ATED) Diesel, 8 Valves, 110 BHP
Peugeot 406 Mk2 (1999->2004) 2.0HDi RHS (DW10ATED),RHZ (DW10ATED) Diesel, 8 Valves, 110 BHP
Peugeot 406 Mk2 (1999->2004) 2.0HDi RHY (DW10TD) Diesel, 8 Valves, 90 BHP
Peugeot 607 (2000->2009) 2.0HDi RHS (DW10ATED),RHZ (DW10ATED) Diesel, 8 Valves, 107 BHP
Peugeot 806 (1995->2002) 2.0HDi RHZ (DW10ATED) Diesel, 8 Valves, 110 BHP
Peugeot Expert Combi (2004->2007) 2.0HDi RHZ (DW10ATED),RHZ (DW10BTED),RHZ (DW10CTED) Diesel, 8 Valves, 110 BHP
Peugeot Partner Combi (2002->2011) 2.0HDi RHY (DW10TD) Diesel, 8 Valves, 90 BHP
Peugeot LCV Boxer Mk2 (2002->2006) 2.0HDi RHV (DW10UTD) Diesel, 8 Valves, 85 BHP
Peugeot LCV Expert (1996->2007) 2.0HDi RHZ (DW10ATED) Diesel, 8 Valves, 110 BHP
Peugeot LCV Expert (1996->2007) 2.0HDi RHX (DW10BTED) Diesel, 8 Valves, 95 BHP
Peugeot LCV Partner (1996->2002) 2.0HDi RHY (DW10TD) Diesel, 8 Valves, 90 BHP
Peugeot LCV Partner (2002->2011) 2.0HDi RHY (DW10TD) Diesel, 8 Valves, 90 BHP
Suzuki Grand Vitara (1998->2005) 2.0TD RHZ Diesel, 8 Valves, 107 BHP

Diesel 2.0 Turbos very similar

5303-970-0018 K03 Peugeot 406
5303-970-0018 K03 Citroen Xantia
5303-970-0018 K03 Peugeot Expert
5303-970-0018 K03 Citroen Xantia Break
5303-970-0023 K03 Citroen Xsara
5303-970-0023 K03 Citroen Xantia
5303-970-0023 K03 Peugeot 306
5303-970-0023 K03 Peugeot Partner
5303-970-0023 K03 Citroen Berlingo
5303-970-0024 K03 Peugeot 406
5303-970-0024 K03 Citroen Xantia
5303-970-0024 K03 Citroen C5
5303-970-0024 K03 Citroen Xantia Break
5303-970-0024 K03 Peugeot 607
5303-970-0024 K03 Citroen C8
5303-970-0050 K03 Citroen C5
5303-970-0050 K03 Citroen Xantia
5303-970-0050 K03 Peugeot 607
5303-970-0050 K03 Peugeot 406
5303-970-0050 K03 Citroen C8
5303-970-0050 K03 Citroen Xantia Break
5303-970-0051 K03 Suzuki Grand Vitara
5303-970-0051 K03 Geo Tracker
5303-970-0056 K03 Citroen Xsara
5303-970-0056 K03 Peugeot 307
5303-970-0056 K03 Citroen Xsara Break
5303-970-0057 K03 Peugeot 307
5303-970-0057 K03 Peugeot 206
5303-970-0057 K03 Citroen Xsara
5303-970-0057 K03 Citroen Xsara Break
5303-970-0061 K03 Peugeot Boxer
5303-970-0061 K03 Citroen Relay
5303-970-0061 K03 Fiat Ducato
5303-970-0061 K03 Citroen Jumper
5303-970-0063 K03 Suzuki Vitara

Tonight did the earth strap on the gearbox
Done the stabiliser link, thats connected to the anti-roll bar.
Tried to replaced the "rusty bolts" lower ball joint nut anti roll bar end nut.
But the nuts have got the wrong threads.. I took them in but the guy sized them up incorrectly?
Installed new gearbox fill / breather cap on gearbox and installed the missing battery clamp.
Hopefully this project will be done this weekend and then it off to the MOT..

Nice weekend for a tan..While im fixing this van.
struggled to put the air filter onto pipe work between the turbo plastic pipe and the air box. After struggling to get the rubber hose connected to the turbo pipe. `Space is an issue their is none. Managed all that and put the electrics box back. Put the air filter in-feed pipe work back.
Managed to repair the four grill screw points, as the screws had rushed on solid, so had to drill them out and clean them up with a M6 tap. nice new shiny screws installed. Grill back on.
Got the number plate back on and thought Id start it...So nothing???
As the battery is flat...currently charging up.


Found that the Drivers side stabiliser link rubber is well passed its sell by date so will have to change that.
Will bleed the brakes change the air filter before dragging it to the MOT centre.