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Jehb wrote:Little update, failed its MOT on a few bits + needing the head gasket doing so I've decided to call it quits as it owes me a lot of money now and I haven't got the motivation to keep going with it anymore - every time I have it's gotten worse.
Being broken for parts, seats, window doors and whatever is left after selling parts (rolling shell I guess) are provisionally sold.
I'm genuinely gutted..... upset at the amount of effort that you've gone to and put in......
Thanks Vaz! I do appreciate the comment and what a beautiful insight into your life experiences! Certainly it's made me more conflicted but I think I'll be going with my gut and selling up. I can afford to fix it all quite easily now but I think I'll be recouping what I can and saving that money for future projects and plans
I'm a bit of a car nut, among other hobbies/interests so don't worry, I'll always have something to keep me busy!
Also thinking about looking into either a reliable modern van as a daily or more classic van as a side project - something I'm a bit more in love with and can justify spending the £££s on.
Going to have a look at the wiring later though as I have a feeling half of the MOT failures (interestingly some were just advisories on my GFs car) might be solved by just plugging in a wire I disconnected a while back!
That's a real shame, but I've seen your progress. It's really been a mixed bag hasn't it. Are you gonna get another that's a bit more reliable?
For anyone who might be temped to take it on as a project, I looked up the MOT. Nothing huuuge. Wiper, lights etc. Significant ones are an exhaust leak and break sensing valve, which I had replaced once for £90.
Head gasket I've tried to get to in its predecessor the XUD9. It's quite an arse to get to the head bolts round the back. Maybe the DW8 is better access, I dunno. I'd be inclined to give it a bash if it were mine, but maybe if it had the array of issues you've experienced I might feel differently.
Yeah pretty gutted as I thought it was going to be head gasket then finish it up but I've just lost motivation to fix all the other little bits too and don't really want to spend hundreds getting my mechanic to do them either. A shame also as I gave it a little drive earlier and it does run nice and feels good to drive too.
Plan is just to give up for now, maybe go halves with the girlfriend on something better one day now we're both working full time but we did our travels (Asia for 3 months) last year and now both a bit career focused so unfortunately any campervan ideas are taking a backseat for a while.
Tbh if I'd just bought it as is I'd be pretty happy as it really doesn't want much, but unfortunately I bought it with 10x the problems for more than it's currently worth. Nearly given up 5 times or so and every time people have convinced me to carry on. Gotta be realistic this time and say enough is enough, it's no-one elses money but mine getting wasted if it goes wrong again
£2k was always my "if it goes wrong and I lose it all I won't be fussed" amount and that's where I'm at so probably is the best time for it anyway 
Little update, failed its MOT on a few bits + needing the head gasket doing so I've decided to call it quits as it owes me a lot of money now and I haven't got the motivation to keep going with it anymore - every time I have it's gotten worse.
Being broken for parts, seats, window doors and whatever is left after selling parts (rolling shell I guess) are provisionally sold.
Bargain! Looks smart too
It certainly does from a distance haha
No primer or clearcoat so we shall see how long it lasts, but can't get any worse than before!
^^^ Good to know Kenbw2, after battling with getting the cage/base out of mine I thought I'd have been better of just putting the new seat on the old/stock base. Glad the effort wasn't in vein and was actually necessary! In answer to the question I'm 80% sure mine were from a Citroen C8 so in theory the ones at your scrapyard should fit perfectly as long as it has the base included
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Just a little job today. £5 worth of spray cans from Poundland to do a cheap and cheerful "refurb" of my wheels with the help of a mate. Not pretty but for a fiver I'm very happy!




Good news with the engine matters.
Liking the progress in the back too!
Thanks! Yours looks very clean!
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Yesterday my girlfriends dad, master of DIY, came round and helped us with cutting and laying the vinyl flooring.
We've left a little area for a step up and also cut the arch liners so they fit with the raised floor. Just need to clean up the arch liners and add some trim pieces to tidy it up.


Decided to stick down the last of the foil on the ceiling and fit the headliner. We were going to wrap the front and back in a nicer fabric but at this point I've decided to prioritise so the little details like that can come later.
Also finally managed to find a second hand oil cooler at a reasonable price so should have that fitted and head gasket sorted in the next month or so hopefully (if this oil cooler doesn't also have a leak
)


Insulated the floor with some recycled plastic insulation. Very basic but hopefully better than nothing!
Whole floor should hopefully be screwed in soon!

I'm not sure that's a valid VIN. It should start with a VF and be 17 digits. I tried prefixing what you gave with the standard bit but it was too long.
Can confirm it is 100% valid, it's whats on the log book and has worked for a few parts suppliers in the past. Perhaps the Citroen database doesn't recognise the Fiat VIN?
I don't think oil leaking into the coolant would be "oil leak" on the MOT history. Do they even open the coolant reservoir?
Yup thats why I said 'That's not to say the oil cooler won't be all good but it definitely doesn't help the chances' (as in, it's unlikely a linked issue but my mind always goes to worst case scenario
). I would assume MOTs are purely external checks as they never picked up on the oil in my coolant - nor did my mechanic that supposedly serviced it though.
If you wanna give me your VIN (starts with VF7BZWJ...) I can look up on Citroen Service which oil cooler you're meant to have. Can give you a picture and a part number.
ZFA22000086004712 Thanks 
They can fail, the classic problem being that oil fills up the cooling system. They are either ally or stainless, a bit of rust shouldn't be a problem.
This is sort of what I'm worried about. On all the breaker vans I've checked the rage and noticed "oil leak" in the MOT history. That's not to say the oil cooler won't be all good but it definitely doesn't help the chances 
I just got mine off a scrappy. I posted that thread in *checks* June 2017. Had no issues at all since.
You could see my old one had rust on the pipes, so it was clearly shot. If the replacement looks clean inside you might be ok.
Would at least tide you over till you can source a new one.
Found 2 potential candidates and one looks like the left in your pic and the other looks like the right, both listed as DW8 and supposedly not compatible with my vehicle though 
Aah okay thats good to hear as I actually avoided one with rusty looking pipes for that reason, but seller thought it was fine (they obviously just didn't know, not their fault).
Watch out that you get the right one. I have an earlier DW8 (the one with no ECU). I got an oil cooler off a DW8B and it was a slightly different size, and immediately leaked oil everywhere. I think mine was iron/steel and the DW8B one was aluminium too.
I documented the process when I changed mine here: https://frenchcarforum.co.uk/forum/view … =3&t=58040
Thank you! I actually think I saw that post before but it's a massive help and I'll definitely follow that.
I'm really struggling to find an oil cooler tbh, I'm worried a second hand one will just break again. How did yours hold up after you replaced it?
Hey all,
Want to find a replacement oil cooler before I get the head gasket done so I can use it un-bypassed.
Anyone know of brand new options, perhaps a universal one that is the same size/fitment?
If not if you are breaking a 1.9d van with the same and functional oil cooler let me know
Thanks!
Cut all the ply for the floor, just got to insulate it and screw it down. We're having a gap on one side to lay down some door mat material. I decided to cut it in this way as it makes use of 1 sheet of 2440 x 1220mm perfectly, with enough left over to fill the rear corners if need be.

If you try and sell/scrap you will get back next to jack shit so how about getting a gasket set and DIY. What you got to lose?
Yup! This is sort of what I'm thinking although not sure about doing it myself as apparently you need to drop the engine? My girlfriend seems to have lost all motivation and is saying "but what if something else goes wrong" but that doesn't really negate the fact that I won't get any money for it as is. It's been looked after other than having this oil sat in the coolant so long so hopefully this is the last it'll ask for for a bit. Although I imagine tyres and such could be a possible. MOT soon so we shall see :S
Spoke to my mechanic and he said the block test is fairly accurate and previous oil in the coolant from oil cooler issue is unlikely to have caused it to come back green which is unfortunate as that may have ruled out a head gasket issue 
Thought I'd post a quick update, some good progress and some bad news. This is over the past few months before and after 3 months of travelling.
First off, we made a template for a gear gaiter. Plan is to make one with fabric matching the interior later on:
Secondly we got back from our travels and started on the interior! Insulation begun and battens laid. Hardest bit was getting out that blooming lower bulkhead!:


Now for the bad news. We found oil in the coolant which I believed to be from before the oil cooler was bypassed by the previous owner. We had a block test done and sadly it's come back as a head gasket fault! So now we are trying to decide whether to sell up at a massive loss or to spend £400-500 getting it fixed and carry on. I've spent about £1500 on the van alone now! Runs amazing and pretty solid but already well over budget and haven't driven it once in the year I've had it.
Decisions 
From what I hear, you may struggle to fit it as the factory window doors have a recess to make the window sit flush (i.e the doors are different, not just a stock door with a window in it)
I chose to just buy a door with window already fitted and swap it over, much easier (for me anyway)
Anyhoo this is clearly way too late of a reply anyway haha
Where did you end up getting one from in the end?
Could indeed be, how do I know if I've got a DW8 or DW8B? Will try eurocarparts and such and see if they can suggest anywhere thanks! Imagine they'll just say to go to a dealer.
Anyone know where I could get a brand new oil cooler for my 2003 1.9D from, other than FIAT themselves?
Plenty on ebay for similar vans/engines (like Boxers, Berlingos etc) but having asked the seller they said it isn't the same? hmmm
Hey Jehb
I have 1 up here in Scotland.
I could stick it between a couple of bits of ply and send it down to you. Probably be around 20-25 quid postage. Make me an offer if you like.
Andy
Sorry Andy, I forgot to update this post. Luckily we found a van in the exact same colour with windows and took all the doors off it 
Put the new battery in today and it started first time! It's been sat for so long, I was surprised it started so well. Even better is the odometer works fine with the new battery. Taken it out for the time being to stop it going flat. Very excited to get driving it!
Looks good - the two door windows you have put in have let a lot of light into the back and having the window in passenger side so useful for pulling out at some junctions.
You know I hadn't thought about rear visibility, thats a good point! Still contemplating putting the rest of the windowed doors on but advantage of leaving it now is that we'd have more solid walls to use for potential storage, insulation etc, even if its not as symmetrically pleasing on the outside. 
First of the new side doors is on! Might just leave it with the rear and side as is but will give it a think. Previous owner sealed the P/S handle in place so might be trickier to swap the locks on that side.
Just need to find some pre 2004 plastic side trim to fit to the rest of the van and it'll be looking pretty good - might actually cover a few of the scratches 



I am enjoying reading your progress with the "blue lemon"
- its all taking shape. I hope to be doing something similar with a silver 1.9 WAV Dispatch. I looked for that conversion as it already had the headlining and windows in. It failed MOT on a few more bits than yours! Are you going to fit windows in the side panels or just the rear and sliding doors?
Keep posting.
Glad you're enjoying it! I started this thread as I love looking back and seeing how it's coming along 
Yeah I would have gotten one of the disability/taxi vans but I didn't want windows all the way round, so we can have some solid walls. Has been more troublesome as no headliner or side windows but hopefully will be worth it. A part of me does wish I got a disability van, even the van we took parts off was a lot nicer; electric windows, air con, headliner, side windows etc - although not the usual lowered floor so I wonder if it was custom fitted out for a wheelchair.
Will have to check out your progress when it gets going! 
So finally a bit more progress - if only a little.
After scouring the internet for windows and vans for weeks on end, we found one locally in the same colour that was being scrapped so were able to buy doors with windows for fairly cheap as well as a few other bits. Very nearly travelled 5 hours for one more expensive so very pleased

Only got the back door swapped over so far but should have the others on soon, just wish the days weren't getting so short!
