turbo replacement 2.0 hdi - Peugeot Forums
Peugeot Forums - Peueot - Citroen Community
Home :: Peugeot Forums :: Rules :: Articles :: About Us :: Partner Vendors :: Advertise


Go Back   Peugeot Forums > Peugeot Models > 407
PeugeotForums.com is the premier Peugeot All Forum on the internet. Registered Users do not see the above ads.
Reply
 
LinkBack Thread Tools Display Modes
Old 29-12-11, 10:08 AM   #1
Senior Member
 
markjack411's Avatar
 
Join Date: Nov 2010
Location: folkestone
Posts: 128
Default turbo replacement 2.0 hdi

i need help urgent !!
i have to change blown turbo but looking at it i cant even see it.
has anyone changed one ?
if so how do you get to it to change it.
thanks
markjack411 is offline   Reply With Quote Quick reply to this message
Sponsored Links
Advertisement
 
Old 29-12-11, 12:02 PM   #2
davidireland
Guest
 
Posts: n/a
Default

Yes, an absolute nightmare job.
Whats up with it?
  Reply With Quote Quick reply to this message
Old 29-12-11, 02:21 PM   #3
Senior Member
 
markjack411's Avatar
 
Join Date: Nov 2010
Location: folkestone
Posts: 128
Default

Quote:
Originally Posted by davidireland View Post
Yes, an absolute nightmare job.
Whats up with it?
hi david
the turbo has completelly blown with clouds of smoke pouring out.
could you please help with the procedure for removal as i just cant find any info on the removal.
i am competant enough but just cant see how to get the unit off of the car .
thanks
mark

Last edited by markjack411; 29-12-11 at 02:27 PM.
markjack411 is offline   Reply With Quote Quick reply to this message
 
Old 29-12-11, 05:21 PM   #4
Inactive User
 
Join Date: Aug 2011
Location: Bilston West Midlands
Posts: 1,025
Default

Bare in mind this is the 1.6hdi .

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.

Another thing a peugeot mechanic was telling me is that they usally remove the strainer (altogether) in the turbo feed pipe behind the dpf.


And here is more.

OIL CHANGE PROCEDURE ON ALL DV6 ENGINES

It is necessary to follow a specific oil change procedure on all DV6 and DV6U engines so as to ensure that no used oil remains to mix with the new oil.

The following method must be used:

The engine oil temperature must be at least 50C :
- the engine oil temperature is considered to be at 50C when the water temperature indicator is between 80C and 90C or the cooling fan has cut in
ensure that the vehicle is level (side to side and fore and aft)
remove the oil filter to allow the circuit to drain completely
remove the oil filler cap and the dipstick
remove the drain plug
allow the oil to drain by gravity for at least 10 minutes (DO NOT USE SUCTION METHODS)
fit a new oil filter
refit the drain plug with a new sealing washer
fill the engine with quantity of oil recommended for the engine
refit the oil filler cap and the dipstick
run the engine at idle until the oil pressure warning lamp goes out (about 1 minute)
wait 5 minutes
check the oil level using the dipstick: the level should be as close as possible to, but not exceeding the maximum mark (1) so as to be between (1) and (3)

For information, the lower mark (2) = Min (0%) the upper mark (1) = Max (100%) the intermediate mark (3) =
4 of 4

CONSEQUENCES OF NOT KEEPING TO THE OIL CHANGE INTERVALS

If the customer does not have the oil changed at the recommended intervals, the oil will become excessively polluted and will no longer ensure the correct lubrication of the engine. One of the first consequences is inadequate lubrication of the turbocharger bearings causing a failure which is repeated after the turbocharger is replaced. Subsequent symptoms resulting from the reduced level of lubrication will be a noisy engine and then destruction of the engine.

We remind you that if the customer does not keep to the servicing intervals recommended in the Maintenance and Guarantee Guide, the customer will be responsible for the durability of the mechanical parts of the engine.
In this case, the any related repairs needed are not covered by the new vehicle warranty.

CONSEQUENCES OF NOT FOLLOWING THE OIL CHANGE PROCEDURE

If the oil changes are not done as described above, all deposits of old oil will not be removed and will very quickly pollute the new oil, accelerating the ageing of the oil in the engine lubrication circuit (even causing the oil to congeal).

The consequences for the engine are the same as if the oil change intervals are not observed. As a result, any related repairs needed are not covered under the new vehicle warranty.


Quote from an independent garage....
There are big problems with poor oil change routines on 1.6HDi's causing oil clogging in cylinder head galleries, turbo supply lubrication pipes etc which is the cause for repeated turbo failure.

When replacing a failed turbo it is imperitive to replace the oil supply/return pipes. You also need to remove the sump and check the gauze on on the pump for any blockages.

Finally a good check so see if there is serious internal blockages, remove the brake vacuum pump - there's a little gauze inside that. If that has signs of blockage then you've got some serious internal clogging going on.

We've had a brand new turbo literally fail within 100 mile from the impellor seizing up and the nut which secures it on the shaft coming undone and wedging in the fan blades. This particular one was an extreme case and ended up having a new engine!
__________________
[B][SIZE="4"][COLOR="DarkRed"][/COLOR]2000 Volvo v70 :thumb:[COLOR="DarkRed"][/COLOR][/SIZE][/B]
nige65 is offline   Reply With Quote Quick reply to this message
Old 29-12-11, 06:54 PM   #5
Inactive User
 
Join Date: Feb 2011
Location: PLYMOUTH,DEVON
Posts: 546
Default

1.6 is on front ,2.0 on tne back
__________________
C4 VTR+ TU5JP4
PP OWNER PLYMOUTH:nod:
magma1974 is offline   Reply With Quote Quick reply to this message
Old 29-12-11, 08:42 PM   #6
Inactive User
 
Join Date: Dec 2011
Location: Lancashire.
Posts: 83
Default

Nige,

Tell me this is not the same as the 2.0 hdi's.

Maj.
icepac21 is offline   Reply With Quote Quick reply to this message
Old 29-12-11, 09:48 PM   #7
davidireland
Guest
 
Posts: n/a
Default

Most of the turbo removal can be got from above. The engine mount is to be removed to get the engine as forward as possible.
There is a pre-catalytic converter which has to be removed first. This is the biggest grief.
If i was you get access to a car lift, it'll make the job a tad easier.
  Reply With Quote Quick reply to this message
Old 30-12-11, 03:12 AM   #8
Inactive User
 
Join Date: Feb 2011
Location: PLYMOUTH,DEVON
Posts: 546
Default

https://rapidshare.com/files/1875784...BO_REMOVAL.pdf
__________________
C4 VTR+ TU5JP4
PP OWNER PLYMOUTH:nod:
magma1974 is offline   Reply With Quote Quick reply to this message
Old 13-01-17, 02:10 PM   #9
Senior Member
 
Join Date: Dec 2016
Posts: 681
Default

Quote:
Originally Posted by magma1974 View Post
Does anybody still have this PDF?

Edit - I believe I have the document, just paid Peugeot 5 euro for an hours access!

Last edited by BiGK; 13-01-17 at 03:45 PM.
BiGK is offline   Reply With Quote Quick reply to this message
Sponsored Links
Advertisement
 
Reply

Quick Reply
Message:
Options

Register Now

In order to be able to post messages on the Peugeot Forums forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.
User Name:
Password
Please enter a password for your user account. Note that passwords are case-sensitive.
Password:
Confirm Password:
Email Address
Please enter a valid email address for yourself.
Email Address:

Log-in


Thread Tools
Display Modes

Posting Rules
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On



All times are GMT. The time now is 03:23 AM.



Powered by vBulletin® Copyright ©2000 - 2019, vBulletin Solutions, Inc.
Content Relevant URLs by vBSEO 3.6.0
vBulletin Security provided by vBSecurity v2.2.2 (Pro) - vBulletin Mods & Addons Copyright © 2019 DragonByte Technologies Ltd.