Fixing Engine's Throttle Body & Headlight on a Jumper/Ducato/Boxer/Relay P0638 -

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Nigel Van Conversion Tech talk
Unfortunately the engine throws an error code after the winter due to water ingress into the throttle body assembly. At the Citroën dealer, it's a 700 € fix, can we repair this ourselves?
This issue is the same on a Peugeot Boxer, Citroen Jumper or Relay and Fiat Ducato 3.0 liter engine made by Iveco. It's caused by a design flaw which leads water ingress to damage the throttle body.
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We are Nikki and Gert, a couple from Belgium, in our early 30's and currently working fulltime.
Last couple of years, we traveled together through parts of Europe, often going on camping trips with our tent and car.
We started following van lifers and digital nomads on social media to get some inspiration. It was then, when we realized that building and owning a camper van was in our grasp, and you didn't need a pile of money to do it.
In 2020, we saw our journey to Texas, USA cancelled, due to COVID-19.
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Опубликовано:

20 апр 2021

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Комментарии : 59

@ritchycamaro 2 года назад

Hi Nigel, nice video. I have a fiat ducato same engine as yours. And I discovered that when it's raining a lot of water runs into the engine bay. I found a couple of videos to deal with this problem. In short: put some butyl sealer between the plastic part below the windscreen and the windscreen itself. That stops a lot of moisture on your engine and saves you from more troubles in the future. Groetjes, Rijk Nederland.

@Euronauts 2 года назад

Thanks! Yes indeed I sealed off the windscreen now. You can also order a special part that replaces the metal bracket for the vacuum valve (where it leaks down). This part contains a drain pipe. I think sealing is easier...

@ritchycamaro 2 года назад

@@Euronauts yes,sealing is a bit more work, but works for the whole motor space. By the way i have just replaced the gearbox oil. There where no problems but i thought its now 13 years old 2008.. i must say using synthetic 75w80 longlife oil from kroonoil works perfect. All is quiteter now. And shifting is very smooth. Perhaps nice video! Chiao

@Euronauts 2 года назад

@@ritchycamaro sounds like something I could do when we are back. Shifting is still smooth but couldn't hurt. How many km are on yours? Mine has almost 120000 now. We bought it last year with few km on it. I also posted a video were we changed all disc brakes.

@ritchycamaro 2 года назад

@@Euronauts mine has 80.000 km. Nice vid about the brakes!

@greenreaper1985 2 года назад

@@ritchycamaro would this water running into the engine bay likely be the cause of my windscreen fogging up quite badly on the inside every time it's raining out?

@ademsadiki3799 3 года назад

Merci pour votre vidéo elle m'a beaucoup aidé 😃

@Semiloju 2 года назад

Merci Nigel Van, excellente video, qui va enfin me décider à remplacer ce foutu boitier papillon!

@Euronauts 2 года назад

Bonjour Luc. Merci et bonne chance!

@bwv. 3 года назад

Cool stuff!

@denisdb725 2 года назад

Mooi Engels gesproken.

@malcolmbass 3 года назад

Bonjour, Merci pour cette vidéo qui m'a bien aidé pour démonter mon boitier papillon

@Euronauts 3 года назад

Salut! Ça me fait plaisir que notre vidéo vous a aidé !

@oh2dx805 3 года назад

Good job there Nigel - well done. +++ Once you get all the problems fixed you will find it is a very good van. I like mine (Fiat version) , but it hasn't been a easy job. Most of my problems have been difficult to fix due to bad and wrong parts being sent by the parts companies , specifically Autodoc. I will never buy from them again. I made a video about my terrible experience with them. I hope that you can avoid similar problems.

@Euronauts 3 года назад

Hi VANDIY, thanks! I watched your video about Autodoc and I'm really sorry about what happened to you. In Belgium you can open a complaint at the Federal Government Service of Economics. Of course this takes a while... I suppose Finland has a similar procedure. I also already noticed many websites leading to Autodoc with a different front. I ordered some parts from them and indeed their shipping is slow. The throttle body itself came from an eBay seller in Germany and the shipping and communication was much faster. Because I thought the throttle body from eBay was bad I ordered the same one from Autodoc... which I did send back a few days later unopened using the "Safe Delivery" option. It arrived a few days ago in Berlin so I'm hoping for a better experience than you in getting my money back (shouldn't be a problem since it was unopened...). \ It's great you offered some alternative websites for buying parts, will take a look at them in the future. I did use many sites for looking up parts and it seems you're never 100% sure about compatibility that's why I will consult some people on sites like fiatforum.com first before doing anything. Most of the time you will notice fairly quickly when something doesn't fit but in your case where something is off by 6mm it really sucks. Anyway, I hope you will get your money back!

@danthomas1445 Год назад

Good video. I have a a 2011/ 2012 3 litre diesel Boxer I am in process of buying. Throttle body was replaced by garage for MOT, but seller drove a day before enfine light came back on. Van back in garage. I am wondering if it needa the magic cable! They can't find a fault code to diagnose. What part is this cable adaptwr please

@strategicthinker8899 Год назад

Just wash the headlight in some detergent and rinse it with a hose inside (after removing it), then reseal it in the weak area with some epoxy or super glue so the moisture doesn't accumulate again. And your throttle body rubber hose popped off the throttle body.

@Euronauts Год назад

That kills the adjustment motors

@adanruano9308 Год назад

Hello nigel good video. I have the same problem but the original connector is missing, the previous owner shorted it. Could you show me with a photo or video in which position the original cables go? I can't see it well in the video. Thank you very much

@arkitecn9642 Год назад

Hello. Do you have the link to buy the wire or the product number?

@christopherclow7688 2 года назад

Hi I have same problem but cannot get frount grill out the way there's a small bracket just under the badge. I think it's impossible to get too the nut .how did yours come off. Thanks Chris

@Euronauts 2 года назад

Hi Chris, I think I know what nut you mean, in the center... For me it was easily accessible so I'm not sure what is going on with yours. If you remove the upper plastic part (with the badge), the nut can be easily removed. If you want you can send me a pic through our FB page and I might be able to help. I need to remove the front again in the next weeks to replace the thermostat anyway....

@FOXY-2023 2 года назад

Did you have black smoke sometimes . And sometimes a lazy throttle. I was told my problems could be the very same as yours on a Citroën relay 2010. But I'm pretty sure my problem could well be the EGR valve . Great video . If it is the throttle body on mine I can now do the job and know where to look for the part lol

@Euronauts 2 года назад

Hey, I didn't have any smoke issues. Also no lazy throttle. EGR and the throttle body work together to regulate the EGR system. Could be that your throttle body is stuck or can't open completely. When hitting the throttle, the EGR should be closed I believe, so I would look at the TB anyway. However, the EGR valve is a much simpler part so couldn't hurt to check it as well! Good luck

@FOXY-2023 2 года назад

@@Euronauts thanks very much for the reply and the info

@chawki000000 2 года назад

Ik heb een vraagje : ik heb een Peugeot boxer van 2006 ik denk dat ik hetzelfde heb als u ofwel vervuilde egr klep blaakbaar na wat rondneuzen op het internet . Als ik geen gas geef of stationair blijf staan valt hij uit maar kan hem metteen terug starten voor de rest geen probleem. Wat denkt u ? Grtz

@Euronauts 2 года назад

Eerlijk gezegd geen idee. Het zou kunnen dat de klep vast zit in gesloten positie. Egr klep lijkt me dit niet te zijn.

@MrDufais Год назад

Hoi Nigel, dank voor je video! Mijn Ducato 2007 multijet 101 pk zaagt bij stationair koude motor. Zou dit het zelfde probleem met het gasklephuis zijn? Stel dat ik het gasklephuis vervang, en ik koop origineel gasklephuis, is dan de adapter misschien niet nodig? Met vriendelijke groet, Martijn

@Euronauts 8 месяцев назад

Sorry Martijn voor het laten antwoord, je comment was me ontgaan. Waarschijnlijk heb je het probleem al opgelost. Vooraleer je naar het gasklephuis kijkt, kan een slechte massa bij dit model ook de oorzaak zijn. En is veel eenvoudiger en goedkoper op te lossen!

@gfxsignals6027 Месяц назад

Hi Euronauts, can this problem explain an over consumption ? I got more than 50% and I currently get a P0638 fault nut no black smoke

@Euronauts 17 дней назад

50% overconsumption? I would rather think an EGR stuck open, the thottle body alone won't cause this I believe.

@robhills2398 9 месяцев назад

Hi Nigel. What was the fault code you had? I have fault codes P0488 and P0490 which the cause cannot be found, different EGRS have been fitted and someone suggested it could be due to the throttle valve. Do you have any Idea?

@Euronauts 8 месяцев назад

Hi, sorry I don't remember exactly which one it was. If you disconnect the throttle valve it will immediately throw that code. It was indeed related to the EGR circuit if I remember correctly.