1.6 Tdci - Replacing Turbo

[Mad85]

My focus is really lacking power and I noticed a new slight whine from (i think) the turbo. Not sure if its dirty or its on its way out but considering the type of damage you would get from a blown turbo I decided to purchase a refurbished unit from eBay for about 300 quid. Not wanting to spend much more on this car (repair bills in the last couple of years have run into thousands already), I am thinking of doing the job myself with my buddy helping me. Haynes manual put the job at 4 stars which I honestly have never done but have found 3 stars jobs pretty easy. I also have a good set of tools and pit in my garage. None the less it is still something that neither me or my friend have ever done - do you think we should do it or is it too risky?

Also apart from the gaskets, what else needs to be changed? The oil feed pipe was replaced a year ago since I decided it was a good practice to do it while I had my DPF being removed.

[Lenny]

My focus is really lacking power and I noticed a new slight whine from (i think) the turbo. Not sure if its dirty or its on its way out but considering the type of damage you would get from a blown turbo I decided to purchase a refurbished unit from ebay for about 300 quid. Not wanting to spend much more on this car (repair bills in the last couple of years have run into thousands already), I am thinking of doing the job myself with my buddy helping me. Haynes manual put the job at 4 stars which I honestly have never done but have found 3 stars jobs pretty easy. I also have a good set of tools and pit in my garage. None the less it is still something that neither me or my friend have ever done - do you think we should do it or is it too risky?

Also apart from the gaskets, what else needs to be changed? The oil feed pipe was replaced a year ago since I decided it was a good practice to do it while I had my DPF being removed.

Hi mark,

Get your self a can of wynnes engine flush, I think the even do a specific diesel version now too,

Pour it in to your oil 15-20 minutes before draining,

Start the engine and hold the revs at 2000rpm for 15-20 minutes allowing engine flush to clear your pipes free of carbon,

Then stop the engine and drop her out,

I'd recommend changing the turbo oil feed pipe again to be safe, and if you can get an inlet penilum from a facelift model this will also help your new turbos life span,

Ford changed the inlet penilum on the facelift model to help prevent turbo failure,

Its the black C shaped plastic pipe bolts on top of the turbo and links turbo to intercooler pipe,

I reckon if you and your mate take your time and wear latex gloves which are easy to dispose and change,

Creating less of a mess everywhere then you should be fine.

I'd use engine flush prior to cutting the new turbo,

And on every service over 90,000 miles

[Mad85]

Thanks for the quick response!

I have considered the use of engine flush many times but there are many conflicting reports of its use on a high mileage engine (mine has 98000miles). Some say its beneficial, others say it will stir up so much dirt that it will do more damage than good and it may clog the engine's arteries! Since my turbo is still functional, i am not too concerned about excessive dirt. When I change the banjo filter a year ago, the filter inside was still quite clean (which was a relieve).

About the inlet pennilum, do you have a picture, maybe the old vs the new? I have one of the latest pre-facelift model and a few things are in fact from the facelift model.

Thanks a lot

Mark

[Lenny]

Thanks for the quick response!

I have considered the use of engine flush many times but there are many conflicting reports of its use on a high mileage engine (mine has 98000miles). Some say its beneficial, others say it will stir up so much dirt that it will do more damage than good and it may clog the engine's arteries! Since my turbo is still functional, i am not too concerned about excessive dirt. When I change the banjo filter a year ago, the filter inside was still quite clean (which was a relieve).

About the inlet pennilum, do you have a picture, maybe the old vs the new? I have one of the latest pre-facelift model and a few things are in fact from the facelift model.

Thanks a lot

Mark

I'd stilll engine flush it mate,

I've just purchased a Levin with 200,000km on the clock,

I've purchased two cans of wynnes and 4ltrs of Castro edge

Aswell as 4ltrs of Halfords cheap oil

I plan to flush with the existing oil,

Then put in the Halfords stuff,

Run for ten minutes

Then flush again,

Followed by putting in the Castro edge,

I reckon if a seals gonna go its gonna go,

Might aswell happen in a controlled environment rather than the motorway,

But I'm sure you will get conflicting information on that.

I'll upload a picture of my 2010 penilum for you to compare

[Lenny]

[Mad85]

hey thanks for this! looks the same as mine so i guess thats one less expense :)

[Mad85]

Mission failed :( could not managed to pull out the turbo since I could not reach two of the 5 nuts securing the turbo :( really disappointed since I spent hours carefully removing everything although it was quite good fun and managed to include a service. Will ask mechanic to do it for me now.

On a separate note anybody knows where the boost pressure controller is? tried to look for it and could not see it anywhere!

[Carl0s]

Changing the turbo is super simple. Loose the clamp that holds the downpipe, unscrew the intake pipe, outputpipe and the oil line. Unhook the wastegate vacuum and bolt off the turbo from the manifold.

Install new seals, bolt the new turbo on, install the downpipe, oilpipe and the air in / out tubes. Shouldnt take longer then 1hour.

Tho, i wonder what has caused your turbo to be goner, mine is driven 300k km and the original turbo works just fine :/ so there might be some underlying problem

The boost controller is on the turbo, there is rod connecting the wastegate to the vacuum controller. The vacuum controller is under the "boos base" fixed whit 3 bolts

[Mad85]

Hey, thanks for this, good to know these engines can live that long! The turbo is not a gonner yet but the variable vanes are sticking which is why I would like to try a new one. I found I could not get to the 2 bottom nuts and even if I did I was not sure if I would be able to tighten them up properly - maybe I chickened out a bit too quickly. Also

Also, not sure if I understood you about the location of the boost controller? I am referring to the pierburg boost solenoid - could not find it anywhere !! Perhaps, can you pin point it on the images submitted above by Lenny?

[Mad85]

Replaced the turbo and pressure boost controller. Did not make much difference and there is a strange whine / whistle on the 1800 rev mark much I believe is when the turbo should start spooling? I can actually feel no boost unless revving hard to around 3000rpm.... not happy at all :'(

Anyway, now I have a serious cutting out problem. revs are not smooth and it would cut out, even when driving. Sometime it would not start at all and the only way to restart it is to clear the ecu faults with a cheap fault reader I am happy to have lying around. There where a couple of errors related to crank shaft position sensor - I have a thread opened for this: http://www.fordownersclub.com/forums/topic/48237-engine-cutting-out-while-driving/#entry295220