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The C15 Champ certainly liked to rust. Mine had more rot on it at 8 years old than my Expert does at 17. It was an 04 too. I see they are making good money now on ebay. The non power steering got too much for my Tendonitis but I do have a soft spot for them. My LDV Pilot with a DW8 Now that really was slow.
I know what you mean about Turbos. On my last Van(Astra) it was not so much the Turbo itself but all the Sensors linked to it that kept putting it in limp mode. It was nothing but grief.
I know what you mean about Slug! Although she Happily got up to Glentrool at a constant 70 last Friday....apart from the hills on the A75! Oh and coming home at 56 on the back of a truck. I used to get 80-85 quite easily out of a Berlingo(much lighter) I had and my old C15 would do 85-90 but they weigh nothing. Just wish I had a 1.9 TD but then turbo's bring all sorts of grief don't they.
Yes everything is made in China now. I have heard bad things said about Bosch parts now they are made there. I guess if you go for one of the bigger names they must at least have better quality control.
I'm waiting on a couple of non car bits from China that seem to be taking forever too. Maybe it's the Corvid 19 holding it up.
Hi Tiree, i'd love a forum sticker or two. Can send SAE
Hi Vaz, went out this morning and she fired straight up so all sorted bar the weeping from fuel housing lid. I did see that genuine housing but funds at the moment are a bit tight so after some research I ordered a PURFLUX one. Apparently it is a trusted make and even Peugeot use their filters.
They aren't as cheap as the crappy Chinese ones but one seller has a few for £29.99. Usually around £80
Link here if anyone interested https://www.ebay.co.uk/itm/Brand-New-Pu … 2749.l2649
When I get it i'll let you know if there should be a seal lower down as well.
Good to know that you only have to open one injector and not all of them to purge.
Ah okay so at the egr end you've just taped the holes up? like the idea of using a blob of sealant
Yes it was a relief not hearing any rattles. It's only done 107k and never let me down. Did you just cut the heads off the bolts to fit into the vacuum pipes?
I've just seen this and think i'll do the same https://www.youtube.com/watch?v=KYjev4ea_aU
Thanks for that Casper. It's starting now as long as it's primed so the leak at the housing seems to be causing the fuel to draw back. I reckon the one way valve will help but i'm definitely going to have to buy another housing lid. Tried two different rings(clamps) and made no difference.
If I hadn't broken the housing lid taking the egr off i'd be all set now 
Got it going! (eventually) but it died and I could see the fuel filter housing was leaking so drawing in air. The pattern part rubber seal is a poor fit. It does go on the underside of the lid and not the housing? Reason I ask is I just saw this https://www.ebay.co.uk/itm/GENUINE-Citr … SwPeRd-24g
And it's thrown me? I'm thinking of putting a one way valve on the clear plastic feed that goes to the pump. Has anyone else tried that?
I shall just keep trawling the net for an original housing lid
I was dreading someone suggesting that Ken lol.
Think that means i'll def have to remove inlet.
Battery is still charging so i'll give it another go and if not try that. Is it best to prime it and not give it any accelerator when I try and start it?
I've never had a problem with her before. Had new glow plugs recently & has always been a great Starter.
Right, all parts fitted today. Tried to start it.. sounded like it might fire up but then died. Primed it and tried several times but it didn't really want to know. A couple of small efforts maybe. Battery is now weak so got it on charge. 
That's great, thanks Casper
Sorry Casper i'm being thick but do you mean the braided hose or the thin rubber one that attaches to the egr?
Haha oh I miss the days of filling my pockets with rotor arms, fuses etc and paying a quid for a dizzy cap for a mk1 escort 
Nice to know there's still some Scrappies you can do that in. My nearest one is about 10 miles away and it's all strictly behind the counter or they might let you in the yard but they search your tool box.
I bet the one I ordered will be a crappy fit too.
Fingers crossed re the rattle. Will let you know how I got on in a couple of days when parts get here. Meanwhile giving the egr a good clean. Is this type possible to blank off?
Right, managed to twist the egr off. It just unscrews but was pretty stuck. Managed to break the nozzle on the fuel housing lid in the process so have had to order another
£16.89 for lid & clamp on ebay (pattern parts). Also bought a new Clip for egr (4.99 on ebay)
Luckily removing the egr left me enough space to remove the broken injector pipe. So pleased I didn't need to remove manifold
Very grateful Casper for telling me how to remove egr. I never would of worked out that it unscrewed.
Just waiting on the parts now. Will update when fitted. Hoping I haven't damaged engine. It gave a terrible death rattle before stalling.
Will attempt it tomorrow. Wish I had smaller hands lol.
Not looking forward to attempting that mate. Not a lot of room at the back is there! Did you manage to get a ratchet to the back ones?
Ken, that photo is a great help thank you. I located the torx screws on the inlet but not sure how i'm going to get them out. Did you use a t27 socket?
I am really hoping removing the egr will be enough as tracing the pipe with my hand it feels like it's the pipe directly behind the valve. Fingers crossed! I will report back tomorrow.
I love D&G Vaz, particularly Glentrool & The Galloway National Park. It's approx. 290 miles from me down here in Lincolnshire so doable in a weekend if I drive through the night on a Friday. I always plan to head further up but I need to do that over more than a weekend. Managed to visit Newton Stewart, Girvan & Stranraer on Saturday after getting to Glentrool at 4.00am and getting about 3 hours sleep. I was planning on going to Loch Awe but I decided it was too far for the Weekend and it's just as well I didn't what with breaking down. Managed to get to County Durham before packing up 
Hopefully I will be back on the road soon and can plan another trip to your beautiful part of the World. Hopefully before the Midge season!
Hi Vaz, Blimey I hope I haven't damaged the teeth on that clip! I wish the pipe was plastic.. unfortunately it's steel and since this morning I've worked out that it's an injector pipe. I've got the nut off the pump end but access to the other is limited. I'm hoping getting the egr off will show me where the other end is! I will report back tomorrow with how I get on. Thanks for your advice.
That's great mate thanks a lot. I'll have a go tomorrow morning and report back. I'm hoping with that out the way I'll have the access I need.
Found this site whilst searching for help!
Here's a pic of my Expert parked up in beautiful Glentrool before the split pipe cut short my wild camping trip.

Thanks for that Casper. I've managed to get that clip off with a small screwdriver but cant see any screws/torx to remove the egr from inlet. I'm starting to think it just pushes in and out but don't want to damage it if i'm wrong.
Sorry I can see it's not a maf now but part of the plastic inlet manifold. are they easy to remove? Would give me better access.
Sorry to join and straight away ask for help but any advice would be very welcome. I own a 2003 Peugeot Expert that I stealth Camp in. I was having a great trip in Scotland before I noticed a strong smell of diesel and decided to head South and home. Managed 90 miles before she gave up and Green Flag recovered me the rest of the way. I've had a look this morning and found a split metal pipe on the pump. Sorry for poor pic quality.
Am I right in thinking this is an injector pipe? I'm a novice mechanic but if it's just changing a pipe I would like to give it a go. Also I can't see how the MAF comes off(to get more access) It's a 1.9d dw8.
Hope someone might be able to help. Thanks, Simon.