If the correct actions are not taken when a turbo blows on these engines then the new turbo will not last long.
These engines need the correct grade of oil used (5w 30 fully syn low ash oil)
and the oil&filter should be renewed every 9k mls (15k kms) or less.
Print off the below info and give it to the garage thats replacing your
You should be able to pick up a reconditioned turbo for around €400.
Peugeot would'nt even charge 2 grand for this job....
Fitting a turbo including following the below actions should take more than a days work.
This is strainer that MUST
be removed when replacing a turbo on the Dv6 engine.
EXTREMELY IMPORTANT INFO REGARDING FITTING TURBO'S ON THE 1.6 HDI ENGINE
RE TURBOCHARGERS: 753420-5005S, 762328-5002S & 49173-07506
PSA 1.6HDi TURBOS 2004+
PLEASE READ THIS BEFORE FITTING THIS TURBOCHARGER!.
The PSA 1.6HDi, DV6TED4 engine is a highly sophisticated low emission, high power diesel unit. It is used in many different applications; Citroen, Ford, Mazda, Mini, Peugeot and Volvo.
Due to the engine being clean and powerful, it is designed to operate at high temperatures, which demands the very best lubricants. These lubricants must be maintained in peak condition and PSA have fitted an in-line oil filter to the turbo and an integral oil cooler/oil filter to this engine to ensure this. However there is a drawback to this; reports in the field indicate that if the engine has been operated with the oil level below normal limits, this may potentially cause a high concentration of carbon in the oil. This may then lead to blockage of the in-line filter, oil cooler and main oil filter, which will eventually bring on premature turbo failure. The vacuum pump may also suffer from this same type of contamination.
However, due to its high operating speeds (230,000 revs per minute) the turbo will usually be the first to show signs of damage. This can happen from 30,000 miles onwards if the oil level and correct oil change intervals/procedure have not been adhered to.
Experience to date suggests that the carbon build up in this application is particularly difficult to remove.
To try to eliminate the potential for further turbo failure, the following MUST be undertaken by the garage, in addition to the normal recommended turbo fitting instructions:
• TURBO OIL FEED PIPE & BANJO BOLTS MUST BE CHANGED.
• OIL PUMP SHOULD BE REMOVED AND CHECKED.
• SUMP MUST BE REMOVED AND OIL STRAINER (PICK UP) SHOULD BE CLEANED/REPLACED BEFORE RE-FITTING NEW TURBO TO REMOVE RESIDUAL CARBON/SLUDGE BUILD UP.
• OIL COOLER AND FILTER ASSEMBLY SHOULD BE REMOVED AND CLEANED.
• REMOVE CHARGE AIR COOLER, DRAIN OFF ANY OIL INSIDE AND CLEAN THOROUGHLY.
• CHECK AND CLEAN ALL INLET AND OUTLET HOSES.
• IF OIL HAS LEAKED FROM PREVIOUSLY DAMAGED TURBO OR ENGINE INTO EXHAUST, CHECK EXHAUST SYSTEM FOR CONTAMINATION/BLOCKAGE (CATALYST, DPF etc.)
• REMOVE BRAKE VACUUM PUMP TO CHECK FOR DEBRIS/CARBON AND CLEAN AS NECESSARY.
• FIT NEW OIL FILTER AND OIL.
• CHECK FUEL INJECTOR GASKETS ARE NOT BURNT OR COMPROMISED. REPLACE AS NECESSARY
• OIL FLOW MUST BE CHECKED:
1. FIT TURBO TO ENGINE LEAVING OIL RETURN PIPE OFF
2. INSTALL A LONGER OIL RETURN LINE AND FEED INTO SUITABLE CONTAINER
3. START ENGINE AND IDLE FOR 60 SECONDS, THEN SWITCH OFF ENGINE
4. MEASURE VOLUME OF OIL IN CONTAINER - 60 SECONDS OF IDLE SHOULD PRODUCE AT LEAST 0.3 LITRES OF OIL.
5. REPEAT TEST TWO OR THREE TIMES TO CONFIRM OIL FLOW IS CORRECT
6. DURING THIS TEST, DO NOT ALLOW ENGINE TO RUN BELOW MINIMUM OIL LEVEL!!
7. VEHICLE SHOULD BE DRIVEN 20 to 30 MILES THEN THE OIL/FILTER REPLACED AGAIN.
Firstly put a good oil flush in the engine for about 20-30 mins. Drain engine oil and change filter. Refill oil with a quality fully synthetic oil.
This can help prevent intial turbo failure.
If Turbo has failed: Remove turbo, oil feed pipe to turbo, oil return pipe from turbo, brake vacuum pump, engine sump and oil pickup pipe/filter.
Where turbo pipe bolts to engine block, blow through engine block to clear any debris that might be in there. Fully clean the brake vacuum pump as
you will find that there is swarf collected. Fully clean out the sump along with the intercooler. Discard the sump pickup and fit new pickup and filter.
fit new turbo oil feed and oil return pipes from turbo. Fit new banjo bolts on oil feed pipe, but firsly remove the gauze filter that is in the banjo
bolt that secures pipe to block. fit new turbo, oil filter and good quality fully synthetic engine oil. Use vehicle for approx 500 miles,
then add oil flush as above and fit new oil and filter