Peugeot Boxer X250 cold start problems

gplatt2000

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Feb 10, 2018
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Hi all

This is my first post and I’m wondering if anyone cal help with a mechanical problem I’m having…

I have a 2007 Peugeot Boxer (X250 / Ducato / Relay) with the 2.2HDI engine (which I believe is a Ford Puma - not the Iveco unit in the Fiats). Since I bought it (2 years ago) I’ve been having an issue with starting in cold weather. Below about 2°C the engine will struggle to start, as shown in the video here:

https://photos.app.goo.gl/ZwdlVJk69VeMChv82

It’s never left me stranded yet (touch wood) – it will usually eventually start after a few attempts. As soon as it’s been running (for even just a few minutes), it will always start fine again. So it’s only ever happened when left overnight.

I fitted a new battery a couple of weeks ago but that’s not solved it. No error codes showing from OBD. It was serviced a few weeks ago (oil change, new air/fuel/oil filters) and that didn’t help. I had it at the mechanics, but they couldn’t recreate the issue – it only happens when it’s really cold, and even then maybe only about 30% of the time.

Has anyone experienced this problem, or is there a known fault? I’ve read about water ingress problems which can effect glow plugs and fuse/relay box. Other than that, I’ve no idea: I’m not at all mechanically knowledgable! The ‘crunching’ sound (at end of video) in particular sounds worrying.

Any help much appreciated – thanks in advance.

Gavin
 

Jim

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Hi Gavin

Just to let you know that you aren't being ignored. Your post has only just this minute gone live as we moderate first posts that have links in them in our fight against spammers. People can see your post now (y)

Thanks
 

MH 55 FUN

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Your digital oil level readout is showing 5 empty squares - how's the oil level ?
The battery sounds like it's struggling to turn the engine over.

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Feb 15, 2014
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oil level readout is showing full you get less squares as level goes down. i would check and clean all earth straps and maybe add an extra one
 
Feb 15, 2014
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Odd - our digital oil level on our old X250 Peugeot showed 5 darkened squares when the level was full.
My 2007 shows less squares when it was down a bit before last service showed 4 or 3 if parked up with nearside wheels on kerb

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Two on Tour

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Down one square.

oil.jpg
 

Euphony

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3 years of weekending with the odd month here and there.
I know it’s not a motorhome so not like for like but I had a Mazda RX8 many years ago and they are renowned for both cold and hot start issues, in the end I needed to replace a standard battery with the highest cold crank amp battery I could find, it solved the issue instantly.
 

Mr B

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Sounds like the battery is bolloxed:)

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gplatt2000

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Wow, didn't expect so many replies so soon, thanks everyone. Had no idea those blocks represented oil level so thanks for pointing that out.

I replaced the battery two years ago with a Yuasa that had come highly recommended so I hope it's not the battery.

I'll check earths tomorrow and get multimeter on the battery, and report back.

Thanks again
 
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gplatt2000

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Forgot to say, I ran some 'Wynns Xtreme Diesel System Cleaner' through about 3,000mi ago and I've (mostly) used premium diesel since. Worth trying some injector cleaner too I suppose.

Fingers crossed it's a dodgy earth, will look into starter motor if not.
 
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gplatt2000

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Edit: replaced battery two weeks ago (not two years ago!)

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TheBig1

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putting a jumplead from battery negative post to the engine block will show if its an earth strap. clean the terminals too when the battery is uncovered
 
Jun 4, 2016
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did you check or replace the glow plugs ? as surely if it ALWAYS starts when warm would this be an earth issue ?
 

TheBig1

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poor earth = weak glow plugs
poor earth = poor starter till engine warm

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May 31, 2015
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it only happens when it’s really cold, and even then maybe only about 30% of the time.

I gotta be honest my first thought was an air leak too , however reading the rest of your post in particular the above sentence , lead's me to suspect it's electrical . Now as you mention this being an intermittent fault , i'm afraid i would suspect damp is involved somewhere . The problem is that newer vehicle's are loaded with electric's , that diesel engines don't need , so my guess would be , it could possibly be breaking a signal down somewhere , from say the crankshaft position sensor . This particular sensor , need's to show two clear revolution's before the engine will start , if this was interrupted in some way , it could delay starting . I'm not saying this component is the fault , but just using it as a , for instance , the fly in the ointment with this opinion , is that you say you don't have any warning's on the dashboard . Now being honest , not being familiar with this type of motor , i can't comment on that any further , except to say , that as the engine does start , maybe the ecu does not see this as a fault . This damp theory could be further reinforced , if your workshop kept the vehicle inside overnight , preventing the engine from getting damp in the first place .

It's only an opinion , for what it's worth , but what can you do about it . Well personally i would leave it alone for now , keep it in check , and note the weather condition's when you do have problem's . I would suggest you spray all the electric's with a silicon based spray or failing that wd40 . This would give you a degree of damp protection due to their water displacing qualities , other than that , not much , one of the worst fault's to find are intermittent . You think you have it , then bang it all start's again .
Many years ago when i was younger and greener , i once spent hundred's of pound's in an attempt to locate a problem with one of my petrol engined cars . I never did find it even though i replaced most of the ignition system , and it still had it when i sold it , 15 years later .


Sorry .

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Louis

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Yup, agree with - sounds like starter or poor earth connection,
(y)
 
Aug 18, 2014
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As others have said I'd be looking at the earthing as if that is a new battery it should be spinning the engine over far faster than that , even allowing for the fact that it is energising the glow plugs. Additionally as has been mentioned by others I would also have got the biggest cca battery that would go in the space.
 
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I recently had a similar problem with a VW Golf diesel, a diagnostic scan indicated an incorrect reading on a coolant temperature sensor, when the sensor was checked in situ with a meter it was within range so ok, turned out to be a poor connection on the plug even though it appeared 100% perfect, a squirt of contact cleaner and a wriggle of the connector fixed the fault.
A diagnostic scan when stone cold may help but intermittent faults are often difficult !

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gplatt2000

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I checked and cleaned up the battery --> cab earth strap yesterday, but unfortunately that didn't solve it. It's in the garage later this week for its MOT so I'll ask them to replace the engine earth strap and see if that helps.

I'll post back as anything develops, but as it's intermittent it might be a while. Interestingly someone else did mention a dodgy sensor – "A common problem with early X250 vehicles is sloppy temperature measurement. At temperatures a few degrees above freezing the ECU thinks it doesn't need the glow plugs, so the vehicle is hard to start, while below freezing point it starts fine." – so I'll be keeping a log of weather. Might brave some Scottish skiing where hopefully it'll get properly cold!

Thanks again for all your help.
 
Jun 4, 2016
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I checked and cleaned up the battery --> cab earth strap yesterday, but unfortunately that didn't solve it. It's in the garage later this week for its MOT so I'll ask them to replace the engine earth strap and see if that helps.

I'll post back as anything develops, but as it's intermittent it might be a while. Interestingly someone else did mention a dodgy sensor – "A common problem with early X250 vehicles is sloppy temperature measurement. At temperatures a few degrees above freezing the ECU thinks it doesn't need the glow plugs, so the vehicle is hard to start, while below freezing point it starts fine." – so I'll be keeping a log of weather. Might brave some Scottish skiing where hopefully it'll get properly cold!

Thanks again for all your help.
Have you any jump leads you could use as a temp gearbox/engine>>Chassis earth strap to see if it makes any difference.
 

Allanm

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I noticed you waited a long time after the glow plug light went out before you tried to start it. Have you tried to start it immediately the light goes out?

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