Volvo Community Forum. The Forums of the Volvo Owners Club

Forum Rules Volvo Owners Club About VOC Volvo Gallery Links Volvo History Volvo Press
Go Back   Volvo Owners Club Forum > "Technical Topics" > Diesel Engines

Notices

Diesel Engines A forum dedicated to diesel engines fitted to Volvo cars. See the first post in this forum for a list of the diesel engines.

Information
  • VOC Members: There is no login facility using your VOC membership number or the details from page 3 of the club magazine. You need to register in the normal way
  • AOL Customers: Make sure you check the 'Remember me' check box otherwise the AOL system may log you out during the session. This is a known issue with AOL.
  • AOL, Yahoo and Plus.net users. Forum owners such as us are finding that AOL, Yahoo and Plus.net are blocking a lot of email generated from forums. This may mean your registration activation and other emails will not get to you, or they may appear in your spam mailbox

Thread Informations

Blown Turbo on 05 S40 1.6d

Views : 12373

Replies : 21

Users Viewing This Thread :  

Reply
 
Thread Tools Display Modes
Old Jan 17th, 2011, 20:07   #11
Biotoxic
Master Member
 
Biotoxic's Avatar
 

Last Online: Dec 30th, 2018 09:33
Join Date: Oct 2010
Location: Craigavon area
Default

I am stripping off the engine completely. Found some nasty carbon deposits on cylinder head, especially in third cylinder, removing every moving part and deep cleaning it, after that it should last without problems for at least 50 000 k (that's what I think)
Biotoxic is offline   Reply With Quote
The Following User Says Thank You to Biotoxic For This Useful Post:
Old Jan 17th, 2011, 20:13   #12
grass hopper
Premier Member
 
grass hopper's Avatar
 

Last Online: Mar 18th, 2011 14:38
Join Date: May 2009
Location: grassmere!
Smile

Quote:
Originally Posted by S40Matt View Post
I had a conversation with a turbo specialist today who informs me that these engines suffer with carbon build up in the filters around the oil system.

He advised that the sump and oil pump be removed and cleaned among other things but he was quite vague when I tried to get more information from him.

Can anyone shed any light on the full list of filter that will require removal and cleaning?
Volvo brought out a technical report for turbo failure,they should be able to get a print out of vida at the main dealer.

been a few years since i looked at it but the information above sounds correct from the turbo specialist.
__________________
grass hopper is offline   Reply With Quote
Old Jan 18th, 2011, 00:42   #13
S40Matt
Senior Member
 
S40Matt's Avatar
 

Last Online: May 16th, 2015 23:08
Join Date: Jan 2011
Location: Bristol
Exclamation Found it!!

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. However there is a drawback to 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:

• TURBO OIL FEED PIPE & BANJO BOLTS MUST BE CHANGED.
• OIL PUMP SHOULD BE REMOVED AND CHECKED.
• SUMP MUST BE REMOVED AND OIL STRAINER (PICK UP) SHOULD BE CLEANED/REPLACED BEFORE RE-FITTING NEW TURBO TO REMOVE RESIDUAL CARBON/SLUDGE BUILD UP.
• OIL COOLER AND FILTER ASSEMBLY SHOULD BE REMOVED AND CLEANED.
• REMOVE CHARGE AIR COOLER, DRAIN OFF ANY OIL INSIDE AND CLEAN THOROUGHLY.
• CHECK AND CLEAN ALL INLET AND OUTLET HOSES.
• IF OIL HAS LEAKED FROM PREVIOUSLY DAMAGED TURBO OR ENGINE INTO EXHAUST, CHECK EXHAUST SYSTEM FOR CONTAMINATION/BLOCKAGE (CATALYST, DPF etc.)
• REMOVE BRAKE VACUUM PUMP TO CHECK FOR DEBRIS/CARBON AND CLEAN AS NECESSARY.
• FIT NEW OIL FILTER AND OIL.
• CHECK FUEL INJECTOR GASKETS ARE NOT BURNT OR COMPROMISED. REPLACE AS NECESSARY
• OIL FLOW MUST BE CHECKED:
1. FIT TURBO TO ENGINE LEAVING OIL RETURN PIPE OFF
2. INSTALL A LONGER OIL RETURN LINE AND FEED INTO SUITABLE CONTAINER
3. START ENGINE AND IDLE FOR 60 SECONDS, THEN SWITCH OFF ENGINE
4. MEASURE VOLUME OF OIL IN CONTAINER - 60 SECONDS OF IDLE SHOULD PRODUCE AT LEAST 0.3 LITRES OF OIL.
5. REPEAT TEST TWO OR THREE TIMES TO CONFIRM OIL FLOW IS CORRECT
6. DURING THIS TEST, DO NOT ALLOW ENGINE TO RUN BELOW MINIMUM OIL LEVEL!!
7. VEHICLE SHOULD BE DRIVEN 20 to 30 MILES THEN THE OIL/FILTER REPLACED AGAIN.

Another thing a peugeot mechanic was telling me is that they usally remove the strainer (altogether) in the turbo feed pipe behind the dpf.


And here is more.

OIL CHANGE PROCEDURE ON ALL DV6 ENGINES

It is necessary to follow a specific oil change procedure on all DV6 and DV6U engines so as to ensure that no used oil remains to mix with the new oil.

The following method must be used:

• The engine oil temperature must be at least 50°C :
- the engine oil temperature is considered to be at 50°C when the water temperature indicator is between 80°C and 90°C or the cooling fan has cut in
• ensure that the vehicle is level (side to side and fore and aft)
• remove the oil filter to allow the circuit to drain completely
• remove the oil filler cap and the dipstick
• remove the drain plug
• allow the oil to drain by gravity for at least 10 minutes (DO NOT USE SUCTION METHODS)
• fit a new oil filter
• refit the drain plug with a new sealing washer
• fill the engine with quantity of oil recommended for the engine
• refit the oil filler cap and the dipstick
• run the engine at idle until the oil pressure warning lamp goes out (about 1 minute)
• wait 5 minutes
• check the oil level using the dipstick: the level should be as close as possible to, but not exceeding the maximum mark (1) so as to be between (1) and (3)

For information, the lower mark (2) = Min (0%) the upper mark (1) = Max (100%) the intermediate mark (3) = ¾
4 of 4

CONSEQUENCES OF NOT KEEPING TO THE OIL CHANGE INTERVALS

If the customer does not have the oil changed at the recommended intervals, the oil will become excessively polluted and will no longer ensure the correct lubrication of the engine. One of the first consequences is inadequate lubrication of the turbocharger bearings causing a failure which is repeated after the turbocharger is replaced. Subsequent symptoms resulting from the reduced level of lubrication will be a noisy engine and then destruction of the engine.

We remind you that if the customer does not keep to the servicing intervals recommended in the Maintenance and Guarantee Guide, the customer will be responsible for the durability of the mechanical parts of the engine.
In this case, the any related repairs needed are not covered by the new vehicle warranty.

CONSEQUENCES OF NOT FOLLOWING THE OIL CHANGE PROCEDURE

If the oil changes are not done as described above, all deposits of old oil will not be removed and will very quickly pollute the new oil, accelerating the ageing of the oil in the engine lubrication circuit (even causing the oil to congeal).

The consequences for the engine are the same as if the oil change intervals are not observed. As a result, any related repairs needed are not covered under the new vehicle warranty.


Quote from an independent garage....
There are big problems with poor oil change routines on 1.6HDi's causing oil clogging in cylinder head galleries, turbo supply lubrication pipes etc which is the cause for repeated turbo failure.

When replacing a failed turbo it is imperitive to replace the oil supply/return pipes. You also need to remove the sump and check the gauze on on the pump for any blockages.

Finally a good check so see if there is serious internal blockages, remove the brake vacuum pump - there's a little gauze inside that. If that has signs of blockage then you've got some serious internal clogging going on.

We've had a brand new turbo literally fail within 100 mile from the impellor seizing up and the nut which secures it on the shaft coming undone and wedging in the fan blades. This particular one was an extreme case and ended up having a new engine!
S40Matt is offline   Reply With Quote
Old Jan 25th, 2011, 14:03   #14
S40Matt
Senior Member
 
S40Matt's Avatar
 

Last Online: May 16th, 2015 23:08
Join Date: Jan 2011
Location: Bristol
Default Engine flush

http://www.wurth.co.uk/product-0893558.php

Has anyone ever used Wurth engine flush or know if it could do any harm to my engine?
S40Matt is offline   Reply With Quote
Old Jan 31st, 2011, 16:05   #15
S40Matt
Senior Member
 
S40Matt's Avatar
 

Last Online: May 16th, 2015 23:08
Join Date: Jan 2011
Location: Bristol
Default Job done

I have finished fitting the turbo and everything is running really well. If anyone has to do this job on a 1.6d S40 please do not hesitate to PM me with any questions. Thanks to everyone that helped me with this!
S40Matt is offline   Reply With Quote
Old Mar 6th, 2011, 11:41   #16
blueboy81
New Member
 

Last Online: Apr 15th, 2011 22:40
Join Date: Dec 2010
Location: liverpool
Default

Hi Matt. Just after your help as i'm doing the same job as turbo my has blown. One thing i noticed while removing the old turbo was there is no gasket from turbo to engine inlet manifold.... surely this is not correct?.
blueboy81 is offline   Reply With Quote
Old Mar 6th, 2011, 13:23   #17
Biotoxic
Master Member
 
Biotoxic's Avatar
 

Last Online: Dec 30th, 2018 09:33
Join Date: Oct 2010
Location: Craigavon area
Default

I've got 1.9 td, it has a metal gasket between turbo and exhaust pipe.
Biotoxic is offline   Reply With Quote
Old Jan 7th, 2013, 14:25   #18
S40Matt
Senior Member
 
S40Matt's Avatar
 

Last Online: May 16th, 2015 23:08
Join Date: Jan 2011
Location: Bristol
Default

Quote:
Originally Posted by blueboy81 View Post
Hi Matt. Just after your help as i'm doing the same job as turbo my has blown. One thing i noticed while removing the old turbo was there is no gasket from turbo to engine inlet manifold.... surely this is not correct?.

I know this is a very late reply so for the benefit of future Google searches, Yes the 1.6d should have a metal compression gasket fitted between the engine and turbo.
S40Matt is offline   Reply With Quote
Old Jan 7th, 2013, 18:32   #19
onks81
New Member
 

Last Online: Jul 14th, 2015 13:53
Join Date: Feb 2011
Location: birmingham
Default

Hi Guys

Is it an easy job to change the turbo can the job be done at home?? looking through the bulletin it seems like a fair bit of work to do, or is it best advised to get the car on a ramp? also any thoughts as to what could have caused damamge to my turbo the shaft seems twisted and there no damage to any of the blades but it seems as though the bearing has gone....

Could you recommend anywhere that i could purchase a new turbo from im from birmingham, and also would it be best to fit a brand new turbo or a remanufactured turbo?.

Thanks

Tony
onks81 is offline   Reply With Quote
Old Jan 7th, 2013, 20:51   #20
Clan
Experienced Member
 
Clan's Avatar
 

Last Online: Yesterday 22:26
Join Date: Jun 2007
Location: L/H side
Default

Quote:
Originally Posted by blueboy81 View Post
Hi Matt. Just after your help as i'm doing the same job as turbo my has blown. One thing i noticed while removing the old turbo was there is no gasket from turbo to engine inlet manifold.... surely this is not correct?.
yes it is correct , no gasket between turbo and manifold on the 1.6D
__________________
My comments are only based on my opinions and vast experience .
Clan is offline   Reply With Quote
Reply


Currently Active Users Viewing This Thread: 1 (0 members and 1 guests)
 
Thread Tools
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off

Forum Jump


All times are GMT +1. The time now is 02:46.


Powered by vBulletin
Copyright ©2000 - 2024, Jelsoft Enterprises Ltd.