Fixing Engine's Throttle Body & Headlight on a Jumper/Ducato/Boxer/Relay P0638 - #VANBUILD tech talk

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Nigel Van Conversion Tech talk

Unfortunately the engine throws an error code after the winter due to water ingress into the throttle body assembly. At the Citroën dealer, it's a 700 € fix, can we repair this ourselves?

This issue is the same on a Peugeot Boxer, Citroen Jumper or Relay and Fiat Ducato 3.0 liter engine made by Iveco. It's caused by a design flaw which leads water ingress to damage the throttle body.

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We are Nikki and Gert, a couple from Belgium, in our early 30's and currently working fulltime.
Last couple of years, we traveled together through parts of Europe, often going on camping trips with our tent and car.
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We quickly figured that we weren't going anywhere during the upcoming year so we decided to start building our own camper van. 🚐

And so, Nigel was born!

[ritchycamaro]

Hi Nigel, nice video. I have a fiat ducato same engine as yours. And I discovered that when it's raining a lot of water runs into the engine bay. I found a couple of videos to deal with this problem. In short: put some butyl sealer between the plastic part below the windscreen and the windscreen itself. That stops a lot of moisture on your engine and saves you from more troubles in the future. Groetjes, Rijk Nederland.

[Semiloju]

Merci Nigel Van, excellente video, qui va enfin me décider à remplacer ce foutu boitier papillon!

[malcolmbass]

Bonjour,
Merci pour cette vidéo qui m'a bien aidé pour démonter mon boitier papillon

[ademsadiki]

Merci pour votre vidéo elle m'a beaucoup aidé 😃

[adanruano]

Hello nigel good video. I have the same problem but the original connector is missing, the previous owner shorted it. Could you show me with a photo or video in which position the original cables go? I can't see it well in the video. Thank you very much

[strategicthinker]

Just wash the headlight in some detergent and rinse it with a hose inside (after removing it), then reseal it in the weak area with some epoxy or super glue so the moisture doesn't accumulate again. And your throttle body rubber hose popped off the throttle body.

[arkitecn]

Hello. Do you have the link to buy the wire or the product number?

[danthomas]

Good video. I have a a 2011/ 2012 3 litre diesel Boxer I am in process of buying. Throttle body was replaced by garage for MOT, but seller drove a day before enfine light came back on. Van back in garage. I am wondering if it needa the magic cable! They can't find a fault code to diagnose. What part is this cable adaptwr please

[FOXY-]

Did you have black smoke sometimes . And sometimes a lazy throttle. I was told my problems could be the very same as yours on a Citroën relay 2010. But I'm pretty sure my problem could well be the EGR valve . Great video . If it is the throttle body on mine I can now do the job and know where to look for the part lol

[robhills]

Hi Nigel. What was the fault code you had? I have fault codes P0488 and P0490 which the cause cannot be found, different EGRS have been fitted and someone suggested it could be due to the throttle valve. Do you have any Idea?

[christopherclow]

Hi I have same problem but cannot get frount grill out the way there's a small bracket just under the badge. I think it's impossible to get too the nut .how did yours come off. Thanks Chris

[gfxsignals]

Hi Euronauts, can this problem explain an over consumption ? I got more than 50% and I currently get a P0638 fault nut no black smoke

[MrDufais]

Hoi Nigel, dank voor je video! Mijn Ducato 2007 multijet 101 pk zaagt bij stationair koude motor.
Zou dit het zelfde probleem met het gasklephuis zijn?
Stel dat ik het gasklephuis vervang, en ik koop origineel gasklephuis, is dan de adapter misschien niet nodig?
Met vriendelijke groet, Martijn

[chawki]

Ik heb een vraagje : ik heb een
Peugeot boxer van 2006 ik denk dat ik hetzelfde heb als u ofwel vervuilde egr klep blaakbaar na wat rondneuzen op het internet .
Als ik geen gas geef of stationair blijf staan valt hij uit maar kan hem metteen terug starten voor de rest geen probleem.
Wat denkt u ? Grtz

[senseihai]

Hi, where is the fuel filter in this 3.0 jumper??!!

[danielamihaela]

Eu am piesa anulata de cațiva ani si merge de rupe, nu scoate fum de loc

[Jonodrew]

Was that a homemade PWM circuit I see?

[senseihai]

I was driving this van today, and for 3.0 liter it’s not that powerful engine