Help needed! Broken down in 35C France... Turbocharger maybe??

[yodeli]

from ebay looks like french for the catch tank is
Séparateur d'huile

Yep, same as décanteur

 

[YoungDave]

So, I've just had a very prolonged, hands-on and instructional conversation with DP+JAY, who has - with the patience of a saint - really helped wrap my head around everything with the catch can issue.

After investigating further, we've also established that (I think) there is nowhere for the catch can to connect to the air system, which is likely why there was a hose absent all along, and most likely why the sump return hose - the initial hose that kicked all this off - was also loose.

This has probably been the case for some time, I was none the wiser merrily driving away, and for now I think I will leave it that way - just keeping an eye on the oil level as I will lose some in the oil vapour.

This takes away the need to find breather hoses & a catch can - for now. I intend to resolve this, but not immediately for now.

yodeli this just leaves the gasket.

DP+JAY has suggested that simply applying a seal of this will be sufficient if the mechanic is happy to do so, if not we have the list of gaskets as suggested by Pete5996 Broken Link Removed.

Do you think you can check wit the garage:
- A is he happy to apply some gasket sealant instead of replacing it; and if not
- B are any of the linked gaskets correct and if so can they get it fast enough?!

And then maybe the saga will end, or at least go on hold!!


All the best,
YoungDave

 

[Emmit]

Ce n’est pas possible.

D'Accord.

 

[yodeli]

- A is he happy to apply some gasket sealant instead of replacing it; and if not
- B are any of the linked gaskets correct and if so can they get it fast enough?!

Will do A ok
Still waiting for an answer for B . I sent the pic you sent me via whatsapp and asked which one they assume is the right one and what is it made of

 

[airwave]

This takes away the need to find breather hoses & a catch can - for now. I intend to resolve this, but not immediately for now.

I'm gonna post these , Dave as i figure they may be of some use to you in the future . Hopefully , this will help with the general layout of what your dealing with ,

Now these have been taken from the front , as i've got my radiator out at the minute . Trying to view the set up from the top , is pretty poor . It's even worst from below , but the area you should be concentrating on is just above the starter motor .

And there you can see , what i'm guessing is the bone of contention . It's tucked right in behind the starter motor , and held by a jubilee clip . Actually all three pipe are , but they are quite tight . As you can see , mine are in poor condition , though my collector box is in good condition . I have ordered a new bottom hose which is also in rough condition , actually it should arrive next week , along with some other bit's to deal with a minor oil leak i also discovered last week , at the base of the dipstick . There are two bolts that hold it in , an allen key type bolt you can just see below that braided pipe , just to the right of the rough looking vertical running pipe . The other is an 10mm bolt on the top , however you will need to pull it forwards to remove it as there is a lip behind , that pushes in to the block .

Take no notice of the other bits lying around , their nothing to do with it . I wanted the rough looking pipe out to access it condition , that's below , and to the left is the oil cooler . Where the rough pipe goes . There is an o ring seal on the lip and you can see the mounting tabs , of course you know this is viewed from the back ,

but turned round , the front view clearly shows the pipe layout , two on the top , one on the bottom . This little box is a bit cleaner than these pictures show now , both inside and out . I hope their useful to you , but they should help you visualize the layout at least .

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[Figaro]

YoungDave

Are you fixed and back on the road now ?

 

[YoungDave]

Figaro yep back on the road. Currently scrambling around the continent running away from corona restrictions, just made it to Italy today after 2 weeks in Switzerland, having had to leave France at short notixe. More problems to fix, but yep I'm mobile.

airwave thanks very much that's really, really helpful. The garage at Dunieres sourced one from a breakers yard and installed. The engine is however leaking worse than it was before, perhaps it could be that O ring from where the old one was replaced. I'll need to keep an eye on it. I understand the top-right hose as you look at it should connect to the air intake system, between the air filter and the turbo, but there is no connection point - at least that I can see. Do you know where yours connects to? Currently I just have that hose off the can to allow the crankcase to breathe (if I've learnt anything!)

Thanks and all the best
YoungDave

 

[airwave]

Do you know where yours connects to?

As i recall , it connects into the bottom hose coming out of the air filter , at the air filter end . I've just come in , from working on mine . I'm busy removing rust and refinishing the front panel , and as such the radiator is still out . Light is pretty poor right now , and my camera hasn't got a flash . So tomorrow when i go out , i'll photograph it for you , and post it tomorrow night . Your be able to see exactly where it feeds into .

On the subject of o ring , yep i suspect mine was leaking as well . So i need to source one myself ! .

 

[yodeli]

YoungDave Nice to have news from you Dave. I was about to ask you to give us all an update. I know all up to the moment you left Dunières for good , but.... the other funsters were waiting for a sum up ... I guess!

Funnily I had a text message yesterday from the garage in Dunières. They were asking for news from you!!! Never seen such a concern up to now. Indeed.. we should make a list of places where you can have good help from a mecanic, like this one.
They were on hols up to tonight. Who ever had a text message from an unkown garage in a foreign country, to make sure you are alright???? Not me... never ever!

 

[YoungDave]

As i recall , it connects into the bottom hose coming out of the air filter , at the air filter end . I've just come in , from working on mine . I'm busy removing rust and refinishing the front panel , and as such the radiator is still out . Light is pretty poor right now , and my camera hasn't got a flash . So tomorrow when i go out , i'll photograph it for you , and post it tomorrow night . Your be able to see exactly where it feeds into .

On the subject of o ring , yep i suspect mine was leaking as well . So i need to source one myself ! .

Thanks airwave I sincerely appreciate it. And if you manage to find an O ring please let me know where from!!

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[YoungDave]

YoungDave Nice to have news from you Dave. I was about to ask you to give us all an update. I know all up to the moment you left Dunières for good , but.... the other funsters were waiting for a sum up ... I guess!

Funnily I had a text message yesterday from the garage in Dunières. They were asking for news from you!!! Never seen such a concern up to now. Indeed.. we should make a list of places where you can have good help from a mecanic, like this one.
They were on hols up to tonight. Who ever had a text message from an unkown garage in a foreign country, to make sure you are alright???? Not me... never ever!

So it's been an adventure yodeli - the brakes failed in Switzerland - real calipers needed replacing. Swiss labour is painfully expensive. So nice that they called to check in.

Aside from that, everything is running fine, but I am losing oil fairly rapidly which I something I need to address. But on the list of concerns, my leaking roof is more important!!

Hoping you are keeping well,
Dave

 

[tacr2man]

O rings are usually easy to source as they are usually a standard size . Available at seals and bearing suppliers .

 

[airwave]

Thanks airwave I sincerely appreciate it. And if you manage to find an O ring please let me know where from!!

Ah , now there , could be a problem . I've not actually started looking yet , but when i do , i've got a large stash here already . That said , if i find one i'll post the size , but if i have to source one outside , then i will let you know . My local shop does not stock that size , i know that already , that's why i have the stash . Trouble is i slipped up when i purchased it , it's a plumbers set , so i may have to source outside , anyway . They may well stock one for the dipstick fitting , the other weep i discovered last weekend .

 

[airwave]

Thanks airwave I sincerely appreciate it. And if you manage to find an O ring please let me know where from!!

Okay Dave , as promised ;

As i recalled , it did fit into the bottom hose , however the piece it does actually connect into is part of the airbox itself , not the hose . Now if you don't have a connection at this point , it maybe a different connection system , which judging by the problems i've had with coolant hoses , is possible , or your airbox has being changed at some point . Now , i've got to be honest , i don't see any reason , why this would have happened , but it is something that is also possible . Take no notice of the missing hose above , it's the main air intake that's bolted down to the bonnet sill . The whole hose has been removed to enable me to work .

A close up of the connection . You can see the jubilee clip for the hose , again the pipe where it connects , is not a separate pipe , it is part of the airbox moulding . On the way to the air box , it passes through some kind of sensor , which i'm sure i've seen in one of your pictures , then it passes through , what i suspect is a PCV valve , i've got a similar fitting on my 24 year old Citroen

Any good to you mate . You can see one of the bodges top centre , in the vacuum system , due for removal shortly .

Now on the question of the o ring , strangely i have one that will fit the breather box , but not the dipstick fitting . However , another internet search was averted , when i did discover an o ring in with the new fitting , so i've also got that one covered . The breather o ring is a 43x3 , and once i've tested it , if ya like , pm me an address , and i'll post you one . Both of mine were discoloured and hard , so it's unlikely they were sealing anything .

 

[YoungDave]

airwave thanks very much for that. Yep I definitely don't have that connection on the moulding. Will have to think of a plan b at some point!

Thanks very much RE the O ring - that would be amazing. I'll PM you the address right now!

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[YoungDave]

O rings are usually easy to source as they are usually a standard size . Available at seals and bearing suppliers .

That's good to know thanks tacr2man

 

[airwave]

. Yep I definitely don't have that connection on the moulding.

Hmmm , curious .

Okay , well i've had a recap of events to date . Your van is a 95 , where as mine is a 2000 . So maybe , it was never fitted that way in the first place . Both vans are a series two , and though you have a 2.5 , and mine is a 2.8 , they are both Iveco engines , pretty much of the same design . However , my engine uses the 2.5 lower half , with a Sofim top half , and 300cc's more . Now my engine is a euro 5 , but i seem to recall reading somewhere , that at some point just prior to that , maybe a crit-air site , engines were not euro classable . I also seem to recall , the closed breather system was part of the emissions regulations , so it's possible you may originally have had , a completely different engine breather system fitted . Now you remember the famous manual i mentioned , well it completely ignores the engine breather system , so that's no help at all . I did say it was incomplete ! .

So , what i would suggest , before doing anything else , IS PUTTING A CALL OUT HERE , to anyone with a 1995 , 2.5 turbo ducato based van , and get them to photograph the engine breather system they have fitted . In particular the hose top right . Do they have one and where does it go ! ! .

ANYONE ?

I suspect the catch tank may have been changed for some reason , prior to you purchasing the vehicle . It's possible , they may not have been able to source the correct tank , and so fitted a later version instead .


Oh , and i've got the address , soon as i've tested it .

 

[YoungDave]

Thanks airwave hopefully we'll find out!