2.2 hdi turbo problem

[swarf]

hi, after a strange noise coming from the turbo followed by bellowing smoke coming from the exhaust we pulled over and phoned the rac, he found that a linkage on some valve to the right of the rocker cover had come away and said the it wasn't releasing the pressure and that the oil seals had blown on the turbo which may have caused more damage, can someone tell me how much it will cost at a garage for a replacement turbo, i've seen that new ones can be well over £1000, so how much will a recon one cost fitted. thanks.

[Doggy]

Hi swarf & welcome to the site.

'a linkage on some valve to the right of the rocker cover' sounds like the swirl flap actuator - this is a common failure, but doesn't affect the turbo - it could have been faulty for some time and you probably wouldn't have noticed.

I think you need a second opinion.

For example, a burst boost pipe could give the problems you describe and is a lot easier / cheaper to fix than a turbo.

Turbo failures are not unknown, but aren't common either.

If you get confirmation it's the turbo, I would look for a 2nd hand one, you coud try Ade the coupe breaker: http://stores.ebay.co.uk/ade1122-406-coupe-parts

HTH

[swarf]

thanks for the reply dogslife, i'm going to take it to the garage tomorrow I like the sound of the boost pipe failing but would the rac have found that as he was trying different things for a good half hour, although he was convinced the swirl valve not working had caused pressure to blow the oil seal in the turbo, we were towing a boat when it went so the turbo was working away quite hard, also when we tow the oil temp gets quite high when going up hill not into the red but it does rise, glad to here a second hand one will be good enough and a lot cheaper, i've only had the pug for a 3 months and love the thing, excellant for space when we go camping I had 53mpg on a 150 mile round trip to southampton last weekand tows our boat no problem

[Doggy]

Since all the swirl flaps do is restict the airflow into half the inlet valves at low engine speeds, it's difficult to see how they could increase load the turbo. It's more likely you have a problem with the vacuum system that operates (among other things) the turbo boost control. This system does not 'fail safe' - in the event of vacuum loss it will default to producing too much boost pressure.

Several owners, (particularly on the 406 coupe forum, where this engine is more common), have suffered over-boost faults, sometimes accompanied by a failure of one of the hoses between turbo & engine, resulting in much of the air leaking to atmosphere after the air flow has been measured by the MAF. The ecu doesn't know all the air isn't reaching the engine, so injects far too much fuel for the actual airflow, which in turn gives lots of smoke and very little power.

Worth checking those hoses out - see if they go 'firm' when you rev the engine. Look / listen for leaks.

[swarf]

cheers dogslife but after getting the car towed to the garage they discovered that the turbo had gone and sucked up a load of oil, this ended up getting pumped into the exhaust, coating the cat and dpf, i've now got a new turbo and exhaust and they have steam cleaned the dpf, they say the cat is oiled up but will hopefully burn off on a good motorway run (it hasn't so far), because of this I have a anti pollution warning come up and the em light stays on.

my first problem is that the car is now gutless when accelerating and I have to stick my foot down to get it up hills, is this because the em light is on, the car used to very nippy when you boot it.

my second problem is the anti pollution warning not vanishing, i've driven about 200 miles but none of these have been on a run on the motorway, do you think it may burn off after a 50 mile drive at 70mph, if not how much would I have to pay for a new cat.

I'm so glad i've found this forum because the people on here seem so much more knowledgeable than themechanics at the garage.

[Doggy]

Two observations:

1). You have little chance of tracing / rectifying the problem without a diagnostic session, preferably with a PP2000 system.

2). Once you are more familiar with the DPF system, you will probably want to remove it to avoid further problems and expense. This sounds a drastic step to take but it's almost certainly where you will end up. There's a fair chance doing this would also solve your current problems.

Have a look at these two posts:
viewtopic.php?f=10&t=12487
viewtopic.php?f=1&t=10429&start=90&hilit=aunty

[lozz]

How long have you run it for since the repair,

if the Cat as been soaked in oil, it couid take a full day running it,
youve got to get the exhaust realy hot to burn it off,

try some adatives, Red ex, etc, it might help,

ive also heard mention, a bit of petrol in the derv tank will help it to run abit hotter, to burn it off,
dont know if thats true tho,

[swarf]

I really like the idea of a defap dogslife but that is well beyond anything I can do, I live in bristol does anyone who can do this live in the area.
we're going to the midlands tomorrow lozz so will see if a couple of hours each way on the motorway clears anything out.