753420-ANY & 49173-07508 5435-0988-0009 110/90/75 HP PSA 1.6 HDi TURBOS, 2004- ONWARDS
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 with 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 from in the field indicates 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.
We have found 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 OR 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:
- FIT TURBO TO ENGINE LEAVING OIL RETURN PIPE OFF
- INSTALL A LONGER OIL RETURN LINE AND FEED INTO SUITABLE CONTAINER
- START ENGINE AND IDLE FOR 60 SECONDS, THEN SWITCH OFF ENGINE
- MEASURE VOLUME OF OIL IN CONTAINER
§ 60 SECONDS OF IDLE SHOULD PRODUCE AT LEAST 0.3 LITRES OF OIL.
- REPEAT TEST TWO OR THREE TIMES TO CONFIRM OIL FLOW IS CORRECT
- DURING THIS TEST, DO NOT ALLOW ENGINE TO RUN BELOW MINIMUM OIL LEVEL!!
- VEHICLE SHOULD BE DRIVEN 20 to 30 MILES THEN THE OIL/FILTER REPLACED AGAIN.
Even after all the above has been carried out we cannot guarantee all carbon/oil sludge will be removed and you could still suffer a premature turbo failure. In the event of premature failure it is common for the impeller/nose nut to “come off”, this is a consequence of a lubrication/turbine shaft failure & NOT a cause of turbo failure.
In any circumstance of a claim being made, proof of the above requirements have been carried out will be required.
UK Diesel Parts Ltd