PEUGEOT BOXER 1.9Ltr Diesel Engine Page 18


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1. Connecting pipes in the engine bay. 2. Diesel Fuel to Pump illustrated   3. Vacuum Pump

Connecting pipes in the engine bay.

There are many confusing connecting pipes in the engine bay. Not very neatly fitted! Each one is important to the efficient running of the engine.

While being important they are rarely checked during a service of the vehicle, except perhaps for appearance. The usual faults can be vibration wear on the exterior walls and collapse of the rubber wall interior.

Below I have included some images of pipes which should be checked. These checks are quite simple and require no skills!.

The Oil Separater

Turbo Pressure to Diesel Pump[1]

Turbo Pressure to Diesel Pump[2]

The Oil Breather pipe comes from below the dip stick to the Air input pipe to the turbo. This is after the Air Filter.

This should be taken off periodically and checked for a clear path, by blowing into it. If this is blocked then it must be replaced.

Turbo Pressure to Diesel Pump[1] and Turbo Pressure to Diesel Pump[2]
The pipe arrowed in Red is taken from the turbo pressurised pipe to the Diesel Pump. When the turbo is activated, this pressure opens a valve in the diesel pump and gives an extra spurt of diesel, while the turbo is pressurising the manifold input.
This should be taken off periodically and checked for a clear path. If the engine seems down on power this is the pipe to be checked for leaks or blockages.

Below is the pipe, arrowed, from below the dip stick to the manifold cover. Again this should be checked for a clear path internally. On my Motorhome, where the arrow is indicating, I found the pipe was being worn through due to engine vibrations.

Also shown in the picture can be seen the air input to the airfilter, turbo output to the intercooler, turbo output from the intercooler to the manifold.

Manifold Breather           Radiator Expansion Tank

Manifold Breather    


Radiator Expansion Tank

There are Three connecting pipes to the Radiator Expansion Tank. One a connecting pipe to the engine block. The other connects to the radiator off side at the base of the tank is the expansion pipe going to the heater network.
The socket and plug attached to the expansion tank is the indicating 'Low Level' connector cables which pass to the Dash panel indicator.
If the expansion tank overflows or the expansion connecting pipes leak. I have found this connector plug and socket will short circuit and indicate a LOW level on the dash. The cure is to clean these connectors, by taking apart, reconnect, then fill the socket and plug with grease to ensure no liquid is allowed to leak down.

Diesel Fuel to Pump 

Diesel path to fuel pump


Fuel Filter advice

Sometimes it is useful to know where the diesel fuel path is followed.  I have shown it above from the diesel tank to the fuel Pump.

The fuel path is taken from the tank to the thermostat housing, where the fuel is heated up before being taken to the fuel filter. Only then is the fuel passed to the Diesel pump. When the engine is up to operating temperature a valve inside closes this path and the diesel from the tank will be sent direct to the engine diesel pump.

I have illustrated it this way as the boxer engine has a maze of pipes which seem to have no purpose. The pipes are fitted for ease of maintenance and not for aesthetic reasons.

Vacuum Pump

In a diesel engine, from the 'Servo' assisted vacuum cylinder unit, operated by the brake pedal.  The 'Servo' is not able to generate enough vacuum to operate the brakes,   This is compensated for by the vacuum pump from the engine. It is located on the near side of the engine, on the radiator expansion tank side, bolted to the engine manifold cover assembly.

Vacuum pump situated on th near side of the engine.

Vacuum pump situated on the near side of the engine.
Click picture for a description.

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