1.6 Tdci Turbo Failure? Here's The Existent Cause

Ford, Peugeot, Mini, Volvo 1.6 Tdci Turbo Fault

In this article nosotros convey a expect at the psyche root drive of turbo failure on the PSA 1.6 Tdci engine. This engine is fitted to a broad diverseness of manufactures vehicles alongside Ford, Peugeot, Mini, Volvo together with Suzuki to refer but a few. H5N1 listing of simply a few of the mutual models affected are:

• Ford Focus 1.6 Tdci
• Peugeot 307 1.6 Hdi
• Mini Cooper D 1.6 9HX engine
• Volvo S80 1.6D DRIVe

Whilst turbo failure is a mutual occurrence on this engine, ane time properly repaired a novel turbo should lastly many thousands of miles.

The drive of turbo failure on the 1.6 Tdci engine starts, non alongside the turbo but instead alongside carbon laid upward up together with the injector seals. Once the carbon builds upward inwards the engine crude oil it volition drive the gauze filter inwards the turbo crude oil feed banjo bolt behind the DPF/Exhaust to block together with starve the turbocharger of oil. 

To stair out the crude oil pull per unit of measurement area lead at the turbo I made a exceptional adaptor for our crude oil pull per unit of measurement area try kit. Your kit may vary thus making the adaptor could live dissimilar for everyone. Here is the how I connected the try kit to the turbo: 

Oil Pressure Test Connected To Turbo

Next I measured to crude oil pull per unit of measurement area hither is the result:

Result Of First Oil Pressure Test

The engine crude oil pull per unit of measurement area at the turbo whilst the engine was at idle was simply about 0.8 Bar or 12 Psi, agency below the recommended 2.3 Bar minimum. It was clear this turbo had failed due to crude oil starvation.

Because the 1.6 Tdci engine leaves the mill alongside a gauze filter inwards the crude oil feed piping bolt the adjacent pace was to take the bolt, take the gauze, refit the bolt together with stair out the crude oil pull per unit of measurement area for a mo time. This pace equally good confirms that crude oil heart together with crude oil pick-up are inwards adept working order. Here is the consequence from the mo crude oil pull per unit of measurement area test.

Result Of Second Oil Pressure Test

The resulting crude oil pull per unit of measurement area alongside the gauze filter removed was 3.4 Bar which is to a greater extent than than acceptable for the PSA 1.6 Tdci engine.

For reference hither is a ikon of the gauze, inwards this illustration the crude oil feed piping was supersede past times some other garage before. However they failed to convey the right steps together with take the gauze filter later on xxx miles, they equally good failed to supersede the injector sleeve crude oil seals together with laid upward clean other traces of carbon from the engine, this resulted inwards the novel turbo failing inside two weeks:

Turbo Oil Feed Pipe Gauze Filter

Next nosotros replaced the turbo together with followed the instructions that came alongside the turbo. The psyche points of which I possess got listed below:

• Oil feed piping together with banjo bolts replaced.
• Oil sump removed together with cleaned.
• Oil selection upward / strainer replaced.
• Oil filter housing / crude oil cooler removed together with cleaned.
• Charge air cooler / intercooler removed together with cleaned.
• Exhaust checked for blockages.
• DPF cleaned.
• Brake vacuum heart removed together with cleaned.
• New crude oil filter fitted.
• Oil furnish piping from turbo removed together with cleaned.

All the inwards a higher house points are critical actions you lot must convey to ensure that a novel turbo volition lastly for thousands of miles. However I missed ane indicate together with it is the close of import business office equally this what volition possess got probable caused the carbon laid upward up inwards the crude oil that ruined your turbo inwards the starting fourth dimension place, together with that is the injector crude oil seals.

The release ane drive of turbo failure on the 1.6 Tdci engine is the laid upward up of carbon simply about the injectors together with the eventual failure of the injector crude oil seals. This is due to the injector sealing copper washer failing, carbon thus builds upward inwards the injector sleeve, this thus rots the injector sleeve crude oil seal, carbon thus gets into the engine crude oil together with volition eventually drive turbo failure.

Here is an ikon of the laid upward up of carbon simply about release four injector inwards this case:

Carbon Build Up Around Injector

Once the injector is removed it becomes clear how the carbon builds upward inwards the injector sleeve, hither it is compared to injector release 3:

Comparing Injector Carbon Build Up

We thus covered the holes together with cleaned the carbon away to break the injector sleeve crude oil seals. Once this was consummate the impairment to the crude oil seals was clear. For reference hither is an ikon looking straight into the injector sleeve:

Injector Sleeve Oil Seal Failed

Now if nosotros compare this to the seal on injector sleeve release 3, it is obvious that the seal on the forth cylinder was damaged sufficiently plenty to let carbon into the crude oil system:

Injector Sleeve Oil Seal In Good Condition

With the seal replaced, the injector sleeves together with injectors cleaned, injector copper washers replaced together with the injectors refitted all that was left was to pose fresh crude oil inwards the engine. 

The lastly pace together with this is equally good critical was to drive the vehicle xxx miles together with thus strip together with take the gauze filter from the banjo bolt on the feed piping to the turbo. The crude oil together with filter was thus replaced ane time again together with the vehicle route tested a farther fifty miles. 

It is recommended that later on the turbo is replaced together with the inwards a higher house physical care for is followed to right the master copy drive of turbo failure, the crude oil together with filter should live replaced every 3000 miles.

I promise this helps anyone that has experienced turbo failure on the 1.6 Tdci engine.