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Goce

Goce's 06 Peugeot 607 Adventures ( headaches)

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I bought this car few days ago and had a hell of an adventure getting it home overheated, blew a radiator hose and all its coolant. Now the real adventure starts to find and fix everything on it so i can trust it.

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Here i where all this started. I found this Peugeot advertised on a local site cheap. The advert was written very badly and only mention a slight coolant leak. I grabbed my car keys and went 130 km away in another city to have a look. On the body and mechanical except tires it was in good shape. The engine is a different story, it producing pressure in the cooling system and there is engine oil in the coolant. After negotiation the price to where it can work for me and cutting his asking price in half we shook hands. I left him a deposit, and went home, next day i went back 130km and transferred the title on my name, return the license plates, get temporary plates, went thru the inspection station and begin my 130 km drive home, the first 50km was fine but then temp gauge started to drop and engine oil temp went up. I stopped and found a DIY radiator hose blow off and dump all its coolant. I attach the hose filled the system with water and continued, next 30 km was holding but then the temp gauge dropped again at zero no indication that is overheating, i stopped and it has spilled out all the water i put in the coolant system combined with engine oil and it won't accept any more it was boiling and spitting. I had stopped at a road works so all the road workers come by and stood around waiting for it to cool down. Then i filled it and made it further 20 km and same again, did the same then took 10km to do it again and last few km i stopped 2 more times but got it home, the first picture is dirty how i got it that night next two are form the next day me washing it. Now i'll be tearing the 2,7 HDI twin turbo engine part by part to fix it. I wanted to share my experience with it and all my struggles.

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Let the adventures begin. I spent some time today, washing the engine bay, from all the coolant and oil that it spilled out. After few hours to dry i drove it around to dry the engine. Then come somewhat tricky task of getting it in the big garage, it so long and so low that it will nose dive if i tried to drive it straight so i had to get couple of my other vehicles out first and drive in at an angle and the last few feet i use a piece of wood to drive on to, to keep the front bumper from scraping. Once i got it in i did not waste any time to loosen all the wheels and got it on jack stands, it's a heavy car, so i used the two jack method and get it high enough so i can get under it.

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Before tearing it down you could short-circuit the water feed of the oil cooler and see what happens.

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5 hours ago, SRDT said:

Before tearing it down you could short-circuit the water feed of the oil cooler and see what happens.

SRDT i looked at cross connecting the water hoses for the oil cooler but they are quick connects that i don't have spare and i don't want to cut the factory hoses. Because there is a lot of oil coming from the middle of the engine right where the oil cooler is located a wanted to remove it and test it separately i'm sure there is some type of gasket that is making a mess there. And the previous owner mention that he had to replace the oil cooler back in 2017 and looking thru the service history this is a third engine and second gearbox, in 2007 it was replaced by warranty. Then in 2014 there is a service bill for 12 grand and both the engine and gearbox serial numbers added. Knowing that i looked at the engine's date's and some parts like the intake manifold has 05 on it but head castings have 2012 on them so i'm suspecting if they replaced it they replace just the long block, the radiator is 2007.

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Let the adventure begin, I started to disassemble the engine, the cooling system, i could see some glue was used on the thermostat housing when i first went to look at it but had no idea anyone could be so stupid to do this. To glue a rubber hose inside the thermostat housing blocking the passages for the heads. I also found that the V of the engine is full of oil leaking from the oil filter or oil cooler. After seeing this mess i decided i'll take out the radiator to clean it. But to remove the radiator i have to remove the front bumper not a simple job, but an hour later it was out along with a lot of other components, this process took me almost an entire day and when i come to removing the back hoses i come to a conclusion that i'll need to remove the entire engine, there simply is not enough space to do the work in the engine bay.

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Last few days i've been taking apart the 607, very dirty and hard work, there is absolutely no space. One other thing i've also been doing is washing the cooling system parts it looks like this car that had this problem for a long time, on all the hoses, housings there is a 3mm this layer of oil sludge, there is a lot of it i've been soaking the parts in oven degreaser and washing them with very hot water but i'm having trouble getting all the sludge out, even after 5 washings there is still coming out, on some parts i can get a brush in them and they clean up well but staff like EGR coolers valves i can't access them. Has anyone had to do this any tips how clean the engine block and rest of the system, outside of the car. Any advice is appreciated. Also if anyone has access to any service diagrams or repair manuals for the 607 or the 2,7 hdi i will appreciate if you share them.

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Today i spent a lot of time in the garage, after finishing pulling some staff around engine and the engine come out, my engine crane is actually bending from the weight. When i pulled the top bolt for the gearbox all the oil and water from the engine wally leaked out and there's a lot. With the engine out i set it on a tire and took the timing belt cover off to inspect the belt and is soaked in engine oil. So a big step forward now the more technical work can begin.

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Wow!  The best I’ve found for oil contamination is diesel, or something like wd40.  Here we have products like Dawn dishwashing fluid which is good for dissolving oil, or Spray Nine heavy duty grease formula, or Simple Green heavy duty.  I usually use the water based cleaners after using diesel or similar to get the bulk off.

I can not believe how dense that motor compartment is!  Looking forward to your updates!

Rabin

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My friend Reiner had one of those, V6 Diesel.  Comfy car but too complicated for its own good!  It's in eastern Europe now.

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Last few days i've been very busy at work but i did found some time to start tearing down the engine for this car, removing the engine wiring harness took some time, removing the covers, pulleys, brackets, hoses and the big thing i removed was the oil filter, cooler housing. The hole in the engine block was full of oil and coolant i had to separate the coolers to get it removed because the intake manifolds stick out but i managed to get it out, now i need to remove the fuel injectors, high pressure pump but removing common rail fuel injectors is not a simple task, i got a new can of penetrating oil and will be spraying the injectors over the next few days. Im still not asking myself why do i do this to my self.

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Today i spent half a day fighting with the fuel injectors i used up an entire can of penetrating oil and lots of bruised ankles but thankfully they all come out undamaged and with all there copper seals, next on the schedule is to make blanking plates for all the openings and i'll like to pressurised the engine to see if i can found or hear air leaking.

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After couple more hours of searching on the internet and diagnosing i found that i have a faint noise in cylinder 4 and 6 so this means the heads need to come off. Started with the high pressure pump, cam covers and intakes they all come off, then i had to remove the front and rear timing belt and then started with unbolting the cams and head bolts they are tight very tight one head come off no visible leaks i broke two sockets and one ratchet, than the other side i couldn't unbolt it, so i used the huge electric impact and with 3 bolt left i broke my last 18mm socket i had to stop, tomorrow i'll buy couple more 18mm sockets it's going to be fun cleaning and reassembling it has 24 valves, hydrolic lifters rollers and 4 camshafts.

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Today after work i bought me a new 18mm socket and continued removing the front head. And its good news and bad new, the head gasket is showing signs that it has been over torque on one corner right between cylinder 4 and 6 and one coolant passage. i'll need to do some more cleaning and measuring for straightness.

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Today i bought me a new set of impact sockets and put them to use right away. Started with removing the lower oil pan, 14 bolts and it come off, it uses a preform solid gasket. Then i started on the oil pickup, dipstick tube and upper oil pan. Then i bit decision time come, no machines wanted to resurface the desks with it assembled, so first thing i did is remove the back cover bolts and seen it doesn't have any thing holding it other then some silicone so i can remove it with the crank. So the oil pump come off then the pistons one by one. And in few hours the engine was apart, now i'm committed i'll be getting new seals and cleaning everything so i can repair it correctly.

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On 3/7/2020 at 5:13 PM, SouvenirCup said:

Great job. I’ve always like that era of Peugeot’s design. That engine looks pretty daunting!

I personally like the pininfarina designs better but the older cars have less technology less gadgets and by now they all have more then half a million km on them. 

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Today i started on striping the cylinder heads, someone has installed land rover glow plugs in them, they have the same engine but the glow plugs are a bit fatter in fact they are press fit. i spent lots of time, heating them, using couple of types of penetrating oil they all started to turn but won't come out i managed to get out one in the middle and broke the heads of the other two. I also marked all the caps with letters and removed the caps, rollers and hydraulic lifters. Been frustrated with the stuck glow plugs i welded the broken heads to the glow plug and stopped for today to let them cool down and my nerves take a rest.

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I was reading up on these last week and was curious if we ever got the diesel Jags here as they’d be incredible in a 505...  But seeing how complex these suckers are maybe those old XD3T’s aren’t so bad after all!

Huge props to you for tackling this with such gusto, and documenting yet another build project.

Rabin

 

 

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Rabin, after taking apart this engine to its smallest bits i can tell that is not a good design, the conrods are thinner than on a vespa, and both crank and conrod bearings have no notches to locate them and keep them from spinning a bearing, the engine block has no reinforcing ribs, and the crank is very thin in the middle many of the parts, like the bearings, seals, sensors are from Ford so they are build to a price point. In my opinion best engines peugeot ever made are the XUD series. When serviced per instructions they can run forever, the xud11ate  in my daly driver in my daily driver is past the 2M Km mark and is still going strong. I may spend some more time documenting the assembly to show the good and bad points, the valve train is a work of art both chain and belt driven 24v hydraulic lifters rollers on everyone of them.

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That's good to know Goce - thanks for speaking to the specifics.  

On paper I was just thinking a 2.7L v6 HDI with twin turbos would be a powerful modern engine while remaining very efficient.  Plus it does look very impressive - but it's not a feasible swap at all so it was just a fun mental exercise. 

The XD3T is an old motor, but with modern turbo and boost control and good injection pump tuning I think the 505 could be pretty darn good.  We never got the XUD, but I did get to ride in a 405 with one while in India and it felt fantastic - very quick car for a diesel.

Rabin

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Out of curiousity I did some searching and it looks like this engine was the basis for Ford's new 3L V6 diesel in the new F150...

Cooler yet - looks like it came in a 4x2 configuration with a 10sp auto.  Now THAT would be a cool swap into a 505.  :)  Will have to keep an eye out for wrecked diesel F150's now.

Rabin

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This V6 is a Ford design with very little (if any) technical input from PSA.

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