504 Pickup project,i must be mad!

[matthew]

It was on ebay and not too far from me so i thought why not,needs quite a lot of welding and the engines smoking badly but theres a spare in the back!You dont see many about now so its probably worth saving?Does anybody know if i can get chassis repair panels?

[Admin]

Most excellent. The 504 pickup is quite current in the Peugeot lineup so even main dealers may have stock. Mat (504 GLD) is probably a mine of information.

[504gld]

Hi

There doesnt look to be any repair pannels, I could be wrong. You can still get third party panels, like bumpers, wings bonnets etc. It was 12 years ago the last few made it to the UK or there abouts. I did see this one on ebay myself. The XD2 is known for its long life, when you say its smoking badly - what kind of smoke? Is it heavy white smoke upon start up? Dirty black smoke? Does it start and run once the glow plugs have gone out? Is it leaking oil around the crank?

I would love one myself, but finding a tidy one is difficult as they were all built in India, Nigera and Argentina in the corned beef tin factory I think.

The engine in the back, looks a bit suspect, have a look closely on the cylinder head for the date stamp, it should be the normal circle of dots representing months, and the year e.g. 90 for 1990 in the middle. What does it say? On the spare where is the oil filler cap placed middle or front end on the rocker cover? If this spare is indeed ok, then there are a few jobs to do first before it goes in - crank seals, and sump gasket as these are engine out jobs.

It is worth saving them, a club member has restored a 404D pickup which is lovely, and has been chosen to be one of our vehicles at this years NEC Classic Car Show.

Mat

[matthew]

Yes, i had a feeling they were built over there due to the rust as my other pugs have no rust at all,
The engine starts ok but idles very badly and smokes a white/grey colour at all revs,it does rev up ok and smooths out but still smokes,i think i will try to sort it out before swapping it as it looks very clean inside the rocker cover if that means anything?
The previous owner said the other engine was good though,he seemed a decent guy!
Yes it was on ebay so i went to have a look and made a deal then picked it up on a trailer the next day,i didnt pay much for it which is good!
I will have a look at the spare tomorrow and see how old it is,how will i know if its the right lump?
Thanks for the info,matt.

[504gld]

Just as I thought. You need to advance the fuel pump a little. Slacken off all three allen screws on the pump face, and all the clamps that hold the pipe to the injectors together. Start the engine, slowly by hand move the pump towards the engine (ie from the front view turn anti clockwise). It will be hard to move and you may have to slacken off other pipes slightly, but keep it running. As you move the pump you'll be adjusting the ignition timing, as you turn look for the white smoke to clear, it should do (a helper is a good idea!) If you hear excessive knock, then slightly go back. Dont forget to stop the engine and tighten the allen screws, they are a swine to get at though.

Basically the fuel is being injected at the wrong time at the moment, white smoke is too much air, not enough fuel. If you look on the websites 04 series gallery at the pic of my 504D being winched on to our truck, you can see the smoke I had before a tweek!

[matthew]

Hi,just had a look at the spare engine and it says 92 near the glowplugs and on the top near the injectors its got XD2 IV ,the filler cap is in the centre of the rocker cover which is the same as the one in the car.Ive just been playing with the timing and had to loosen all the unions and a bracket hiding underneath in order to rotate the pump,but,it makes no difference to the smoking and rough idle problem,although i could only move it about 3-4mm from the mark i made,oh well

[504gld]

I found that, you do need to move it quite a bit, the injector pipes prevent you moving it any more, so its a matter of slightly bending them, maybe even disconnecting them from the top of the injectors to move the pump, bend the pipes to the right place. Connect up and start, its going to splutter a bit as a small amount of air is going to get in. See what happens, nothing to loose then if this engine truely dud. (I had a real argument with my dad on this, prooved him wrong! - you should be able to see on the pump the amount of adjustment as the allen screws sit in a curved groove - if you cant move the pump but there is more adjustment then disconnecting pipe work will help).

The spare, just from the pic looked to be a Ford Sierra version, as they have different sumps to that of the 504, must be just the way its lead on its side.

[ayden]

Hi Matt how much did you pay for it ??

[matthew]

Go on,have a guess

[ayden]

im guessing £150 or less ;D

[matthew]

Nice one,£100.Which is a lot less than what it would have fetched at the end of the auction

[matthew]

Ive been taking out the wet carpets this afternoon and found more work :'(It leaks from the top of the bulkhead which i can sort out but its also leaking from behind the servo mounting plate,is there a seal there?And is it much of a job?I hate wet carpets

[504gld]

Ah, the wet feet job. This could be worse that you imagined. Open the bonnet, and unbolt the plate that sits between the bonnet and windscreen. Sometimes a bit tricky to lift out, dont forget to disconnect the washer pipes. Down each side of this channel it drops down in to the wing, and water should drain through the bottom. The drain holes in the bottom of the wings get full of all sorts of muck, and block, hence fills with water and rots out the bulk head. That may be more structural than can be fixed :-(

[chugchug]

Sounds like the local sheet steel merchant may make your acquaintance! At least you haven't paid much & any jobs don't need to be concours condition - good luck.
As for dripping carpets - from my experience you don't need to go to the hassle of buying an old Pug, you can get that in a new Fiat Punto. Needles to say the next car wasn't Italian.

[Admin]

Matthew

Take look at the 04 series gallery on the club website for pick-up/commercial inspiration...and get that grinder out!!