The Dispatch | Expert | Scudo Hub

Glad to report I've now got to the bottom of this issue. It turned out to be the ignition switch. I’ve suspected this for some time, then found a post on Youtube where a guy was replacing an ignition barrel and switch on a Xsara Picasso. The barrel on the Picasso and method of removal look identical - just the electrical connectors are different.

https://www.youtube.com/watch?v=MI_wqkjG7pc

His problem was an intermittent heater blower and when it played up, he wiggled the key in the lock and bingo, it came back on again......simple really. So I thought I’d try the same thing with the Expert when it played up and result, everything worked again! ....for that journey at least.

So I’ve just replaced the ignition switch with a good second hand Valeo one. I had to buy a complete assembly including lock and key from the breakers but it was only £20 for the lot. As I’m sure some of you have discovered, a complete assembly from a Peugeot dealer is £170+VAT. You can’t buy just the switch, you have to get the complete assembly, which I didn’t need and didn’t want to change the key either for obvious reasons. I spotted the cheap assemblies on ebay for around £20 - £25 but alarm bells ring when things are that cheap compared to OE. Has another else tried these ones?

The switch replacement involved having to remove the complete barrel assembly, swap out the ignition switch and replace which is fiddly as anyone who has done it will know.

Now I have a spare lock and key with the wrong combination. At some point I’m hoping I can dismantle the lock and rebuild it with the same combination as the vehicle key. I’ve done it before on a SAAB lock. Has anyone found out if this is possible? I’ll also dismantle the dodgy ignition switch to see if that is repairable and post my efforts on here.

Weird happenings afoot eh!  I mate of mine said my issues could be due to a faulty overload relay (PCM?) Apparently most modern vehicles after around 2000 have them and he says a faulty one could cause the symptoms I'm getting. I can't find any reference to them on the net though.

Thankfully no spinning locks, door closure or temp slider issues. The nearside sliding door central locking doesn't work but I assume that just needs a replacement solenoid. There are various fixing screws missing from the lower dashboard on the drivers side, and the air filter housing bracket in the engine bay. I discovered 2 of the 4 gearbox mount bolts were loose so hastily sorted that out. Also the wheelchair passenger seat belt spring mechanism needed a rebuild after 'exploding'.
My brother has a 54 plate 1.9D Dispatch and we've been swapping notes His engine breather pipes are plumbed in differently from mine. Not sure if one or other of the vehicles is plumbed wrongly.
The other thing I would like to figure out is how to operate the heated rear screen elements. The rear screens appear to be wired in but there is no switch on the dash where it should be according to the handbook, next to the hazard warning switch. Being as the van has been converted, I've no idea if the rear screens were there from new or were added as part of the conversion.