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The dreaded 1.6 hdi turbo cancer cure.
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stewpot1776

Posted: Sat Nov 02, 2013 4:05 am

Joined: May 11, 2010
Posts: 24
Trade Rating: 0
Location: South Wales

Hello,

It's been absolutely ages since I have been on here, I hope everyone is well. I thought I would write a quick little bit of advice for some people that might be in my position in the future before I forget too much. I made my move from my loved GTI to the 1.6hdi cc. I love the car because it handles way nicer, more stiff, back end is a little skippy, not much power but great mpg's as I'm a motorway man. Until I learnt about the turbo failure which in going to call the cancer of the 1.6 hdi or coronary of an engine which goes into cardiac.

Driving back from London on the M4 heading home to Wales passing J17 and I'm cruising a steady 75-80 averaging around 46mpg. Then a feel a loss in power with no ummmfff or boost shall we say. No EM light only a filter fault. Confused and baffled I pulled over and called the AA to which he said ahhh turbo is ..... Dead! I knew nothing about turbos, or this engine. Whilst waiting for a lift home in a truck I sit and google my life away seeing endless amounts of threads and posts about this engine and turbo. I bricking it now as I seen the costs of people paying £1000 - £1600 per time. I'll be honest I could not afford that. So I research how to replace a turbo. 6 hours plus they said, we did it in 4. I spent £300 on a turbo from Poland. £50 on oil cheap and good, £10 on flush and £5 on a filter. Ignoring every recommendation of the usual procedure. I drive home on my 2nd London trip with the new turbo and go past J17 to find a loss in power, I pull over and remove the turbo pipe to feel the propeller or impella. It's swinging around like a plastic bag in the wind. My gut sinks and I feel like crap. I don't bother with calling the AA and I drive the now naturally aspirated hdi home which went a max of 70 and 0-60 in 10 minutes down hill.

I finally pay attention to the instructions and please do: these engines and dirty and sludgy. You will need the following:

1 x turbo cartridge/turbo
1 x oil sump pick up
1 x oil feeder pipe incl banjos and copper washers
1 x new filter
1 x 5/35 C2 oil 5 litres
1 x air filter
1 x gasket sealant (no gasket to replace)

Tools = Hack saw, Hammer, T25 torques and general tools.

Time = 6-12 hours.

Drop oil
Take of oil filter
Remove sump
Clean sump with petrol or degreaser
Clean sump gasket edges and apply sealent
Change oil pick up and inspect
Fit sump
Place new filter oil and air.
Remove front grill, exposing radiator mounts & intercooler.
Undo radiator bolts to allow flexibility unless you want the front end off.
Undo and remove intercooler.
Remove all plastics and butterfly hosing etc.
Remove turbo
Remove DPF (not fun)
Change banjo (remove mesh inside now) and oil feeder
Place back DPF
Fit turbo
Use new banjo and connect to turbo.
Connect all pipes
Restore intercooler and radiator bolts
Return grill
Pray
Run for 10 mins
Test oil return pipe to turbo, this they say should return around 0.3l within 60 seconds. Prepare for it to fill it in 3 - 6 seconds.

Changes to car, currently (touch wood still running 1700 miles after and with a new oil change at 600 miles) change again at 6000 and repeat. Monthly tests on oil flow to turbo advised if you drive a lot.

My engine oil was not that bad when I changed it all and not that sludgy. The oil feeder pipe was clear, sump pick up slightly blocked, oil filter ruined in carbon.

I changed the cartridge this time as the turbo from the first one seemed ok except the cartridge. Reconditioned turbo was ruined as bearing shredded the inside bored a big hole. Actuator was good to keep.

Please check before buying as I bought a cartridge from a dodgy guy and did not fit. The second one was beautiful and come with new gasket and seals.

My only problem now is loss of boost sometimes between. 2700-3200 in 3rd/4th and 5th. I am now gaining 55mpg at 80mph however engine temp is more sensitive and often rises above 90 and and stays at around 102 which is half way between 1/4 and 1/2. Not a problem but it could allow carbon to build. Allow turbo cool time and preferably 5 minutes before stopping as idol cooling is not that effective.

I am a novice but learnt a big lesson, please follow . I have pictures if your ever in a confused mind and need help .

Stu

P.S

I will keep you updates with regards to turbo health for future people.


	Stu

Edward

Posted: Sat Nov 02, 2013 6:04 am

Joined: Feb 08, 2010
Posts: 7045
Trade Rating: +5
Location: In the garage

How many miles are people doing between oil changes on these engines?


	2001 GTi 138, Bilstein Sprint dampers, H&R springs, 21mm Peugeot Sport torsion bars, 22mm rear ARB, Peugeot Sport Group A wishbones, 283mm discs, Goodridge stainless hoses, Maniflow 304 grade 4-2-1 2.5" manifold and system, 200 cell cat, Richard Longman head, 45mm Jenvey throttle bodies, 9.5mm TB spacers, 90mm air horns, Jenvey throttle linkage, Jenvey fuel rail, Aeromotive and Goodridge fuel fittings and braided hose, ITG sausage filter, Radtec custom radiator, Piper Ultimate Road cams, Piper vernier pulleys, Omex 600 ECU. Saxo electric PAS pump, Vibra Technics engine mounts. Samco coolant hoses, TTV steel flywheel, 4.76 final drive ratio, 307 CC 180 ratios. 2019 BMW 530i. 2017 Mercedes C300 convertible.

stewpot1776

Posted: Sat Nov 02, 2013 7:29 am

Joined: May 11, 2010
Posts: 24
Trade Rating: 0
Location: South Wales

I'm going to do 6000 to stay safe from now on, however the rescheduled clock can be set to anything. Peugeot's mechanic site has all the details online of what is recommended for the car.


	Stu

Goldin

Posted: Sat Nov 02, 2013 9:46 am

Joined: Feb 08, 2010
Posts: 108
Trade Rating: 0
Location: Pula , Croatia

I am doing 10000 km between oil changes ( Total Ineo ECS 5W30 ).


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