Don't d v 8 from these instructions when fitting your DV6 Turbo

Turbo Part No. 753420-4, 49173-07502/07503/07504/07505/ 07506/07507

Engine codes: 1.6HDI DV6TED4/ DV6UTED Ford, Citroen, Peugeot, Mazda and others

To those in the motor trade, the mechanical repair field, main dealer suppliers and end users (Joe Soaps): this DV6 engine is a bit of a diva - if you don't treat her right she simply won't perform.  She's highly sensitive and demands only the finest oil (5W/30), regular pampering (servicing every 3500 to 5000 miles), and will be quick to throw a tantrum if she feels in any way mistreated.  Our diva demands a specialised diet- none of your fast food (cheap or inferior oil) - she wants to keep in the best of condition, and poor quality oil and failure to service the engine regularly will result in a build up of carbon (best described as 'killer sludge') and she will be so unhappy she won't think twice about taking  the turbo, EGR valve or oil pump out of commission, at a mighty price to you.  (And don't even think of starving her of oil (letting oil levels go low) - if your engine is starved she will simply destroy all around her)

Once the damage is done, and the killer sludge has invaded your engine, its almost impossible to eradicate it.  Once in it can hide in the smallest crevices, darkest deepest oil galleries, from the hydraulic tablets in the head to the oil lift  pipe found in the sump - nowhere is safe.  This can cause ongoing problems as even if you replace a component such as a turbo or EGR valve with a high quality replacement, it will be prone to picking up traces of the killer sludge from the engine and its life expectancy will be reduced. 

It is extremely important that you read the fitting instructions supplied by us before fitting your turbo. Failure to do so will result in premature failure and you will be declined in the event of a warranty claim.

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.

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:

　

1) Remove the engine sump and check oil pump pick up strainer, oil pump, and all oil galleries for carbon contamination
2)If heavy carbon deposits are identified fit new oil pump, oil pump pick up strainer and clean all oil galleries.

3)Fit a new oil feed pipe, oil feed connectors and oil drainpipes and hoses.

　

4)Remove the gauze filter that is in the new banjo bolt that secures pipe to block.

5)Remove oil cooler and oil filter assembly and clean thoroughly.

6)Remove intercooler, pipes and hoses remove residual oil.

7)Remove the vacuum pump and check for debris/carbon deposits and clean/replace as necessary.

8)Remove the Rocker Cover/Cam Box clean all carbon and sludge deposits from the cover, breather( where fitted) and associated valve gear.

9)Check the Particulate Filter and Cat are not blocked, replace if found to be heavily contaminated with oil from the failed turbo.

10)Clean the Exhaust Gas Re-circulation Valve, induction manifold and all associated pipe work and ensure that the E.G.R. is functioning correctly.　

11)A fully synthetic LOW SAPS 5w/30 oil must to be used.

12)Change engine oil after 200 miles and then every 3/ 5000 miles.

13)Ensure that the particulate filter is regenerated frequently and is not blocked. At least one 50 mile continuous journey every month.

14)Check the fuel injector gaskets are not damaged, replace as necessary.

15)Where turbo oil feed pipe bolts to engine block, blow through engine block to clear debris from the failed turbo and any carbon/sludge preferably using a cleaner before the oil pump is refitted.

16)Leave the oil feed pipe detached at the turbo end, crank the engine over without firing until clean oil is flowing from the pipe. It is convenient to catch the oil in a plastic bag or container. When clean oil is flowing connect the pipe to the turbo.

17)Check oil flow:

a) Fit turbo, leave oil return pipe disconnected.

b) Attach an extended oil return pipe and feed into a container.

c) Start engine, idle for 60 seconds and switch off engine.

d) Oil delivery should show at least 0.3 litres of oil.

e) Repeat test to confirm flow is correct.

f) Ensure during the test the engine is not run below minimum oil level

g) Change oil and filter after 20 miles and then after 200 miles as in step 12)

In some instances even after carrying out these instructions not all of the carbon/ sludge deposits will have been removed resulting in further turbo failure. In these instances the turbo will NOT be covered by the warranty as the failure is not due to a faulty component but failure due to external factors.

In life most of us know there are no guarantees - give yourself the best chance of your turbo surviving by following each and every one of the steps above and double checking to make sure all these steps have been followed.  Cutting corners or skipping steps with such a sensitive piece of equipment is just not worth the risk.  Your warranty is only as good as your fitting of the turbo allows it to be.

Footnote: The only 100% cure to prevent premature turbo failure is to fit a new engine.

We sell this turbo with a 12 month warranty but it's a warranty for parts and workmanship, and doesn't cover damage or failure caused by your failure to follow the fitting instructions and have your vehicle regularly serviced. 

Commonsense Car Parts