Need some help here guys, here's the story...

Taxi comes into work, had no power for 6 months cos he couldn't be arsed having it looked at. I take a look for 5 mins and tell him the turbo bearings are shagged, and the injectors are pissing combustion gasses out passed the washers for a start. Also oil covers the whole engine..

Well the job gets passed over to some fucktard who replaced the above mentioned parts without any further diagnostic checks. He left the injectors loose and didn't prime the new turbo or fit the new oil feed pipe as supplied with it or checked the oil feed in any way.

2 miles down the road and the new turbo has blown and I'm left to deal with it..

I've ordered an engine flush and filter and oil obviously, removed the sump, the oil pickup I would say was quite blocked which I have vigerously cleaned. Vac pipe to the actuator is good, replaced oil feed pipe and checked the return. Literally powerwashed the fuck out of the DPF filter till the crap stopped coming out (he's not going to pay for a new one).

Is there anything else I might have forgotten? I don't want a 3rd turbo shitting itself on me... It was in either limp mode or it was extremely difficult to rev before and after the new parts were fitted

Dan

 

Have seen this at work, it`s a small filter in the oil feed, to turbo, hose. It`s in the output end of block. It should be cleaned or changed on every turbo change

 

Sorry it's a 1.6 not 1.8. There is no filter between the block and turbo.

Cheers anyway bud

 

Are you sure? It`s inside the banjo coupling, so you can`t see it, whitout taking it of. Both 1,6 and 1,8 have this

 

Ah, i'l have a look tomorrow then. Inside the actuall banjo bolt?? I have the new bolts and pipe to put on anyway

Cheers

Dan

 

If you have a new oe one, then it should be a new filter innside that. It`s possible to take it out.
It`s alot of parts, who should be changed if you follow Ford`s instruction, and this one is an important one. They use to be blocked

 

Cheers for that, any idea about the rev/power problem?

 

It could be injectors, but hard to say whitout any diagnostic

 

I'd get it all back together and see how it runs, then start scratching your head if it won't rev!

 

If it goes into limp-mode, check the glowplugs. If they are broke, the car won't go and the mil-light goes on. Common fault on 1.6 tdci engines.

Greetz,

Wouter

 

Well got it back together, gonna get it warm and flush it and change the oil and filter. There is no mil light on btw

Dan

 

had the same on the 1.6 tdci put new turbo on 2 min down the road turbo went so next one we did all of the above cleaned sump pick up new oil feed pipe then ran car with a oil feed pipe of to see the feed ment to be a pint a min on idle stupid cars lol

 

If its like a HDi engine out of the Peugeot's you have to change every part on the list to get you surcharge back and or claim any warranty on the second turbo. My local motor factors gave me a copy of the parts list that is expected to be changed at the same time. The DPF is to be changed along with all oil pipes and the intercooler has to be cleaned.

 

What did it turn out to be then?

Oh and my banjo bolts definitely don't have a filter in them

 

Exactly the same on Ford.

 

Strange, al of them we have done this on at work, have it, also on Mazda3 who have the same engine

 

Ford have a tsb out for this problem.
We have just got a focus just came in today with the same problem turbo shaft has snapped.
I had a quick look at the tsb and it says you have to remove the sump and oil pick up clean it all out do a engine flush build it all back up run it with the turbo return pipe off and measure the amount of oil that comes out after a minute if its under a certain amount new engine required.

Try speaking to your local ford dealer and ask for the tsb i will try to find out what number it is tommorow when im back at work.

Cheers Steve

 

we are now no longer taking these jobs on at work because everyone we have done has come back with in a couple of months with another blown turbo. they were all done properly with every part changed as it should be. i rang ford technical and they said that much shit gets in the engine when they break that it is impossible to get it all out. if they have had more than one replacement turbo the only cure is a new engine.

 

as above we told the guy to get rid had only done 55k on a 56 plate i think the only way is a full engine strip down and clean

 

If I ever do a quote on one of these for a turbo I normally quote on a turbo and engine strip and refresh, they have been a problem for a few years now, the standard when you change the turbo is to replace the oil pick up strainer, clean out the sump/crankcase, remove and clean out oil filter housing and brake vacuum pump, then do an oil change/flush, fill will oil, check flow.

 

YEp,did all that every time. They still fucked up.

 

there a filter under the banjo bolt in the back of the block they get caked up

i fill sorry for the turbo guy who supply the turbos
the pick ups have got finer mesh strainer and use thiner oils now
and block easy