remove hdi turbo and ex. manifold, easy?

[nikeastwood]

the joint between either my turbo and manifold, or manifold to head is blowing on my 207 hdi

looks fairly easy to get the turbo off, helped on this car I am sure as there are no heat shields fitted

I have both gaskets already

easy job or not?

[wheeler]

As far a removing & refitting turbos go i'd say the DV6 engines a pretty easy.

[nikeastwood]

done it

the gasket between turbo and manifold had failed, in fact half of it was missing.

while I was there, I did the manifold to head gasket at the same time

at first I thought it was this, last "mechanic" has cut the clamp/heat shield off and caught the turbo outlet, there was no carbon coming from it so I later filled that slit with chemical metal ****

removing turbo nuts was fiddly

this is the joint that failed, it cleaned up well afterwards

the failed gasket still on the manifold

no wonder it was blowing

cleaned up nice

new gaskets

after lots of swearing and struggling, and less faffing about with oily hands with my camera, its all back together but still seems to be blowing a bit, very noticable when AC kicks on and off, I think the flanges mustnt be very flat between turbo and manifold, a softer, perhaps copper gasket might be best but it will have to wait now my patience is wearing thin but at least I know what the job entails.


am totally covered in oily carbon, as are my tools, but I have done for the day now and will start the clean up operation on my tools tomorrow.




***** probably next year, I will get a replacement turbo, although that crack isnt leaking its not going to be doing any good and could lead to further cracks forming due to the heat strett on the turbine housing.

[nikeastwood]

the tin "gasket" I bought I have never, ever had any luck with them in any car that had that type of gasket used in the exhaust system. I am just going to make my own from some 1.2mm aluminium sheet, that will be soft enough to take up any imperfections in any of the mating surfaces.

its just annoying that I spent a whole afternoon on it, but doing it a second time will be easier as I wont be needing to do the manifold.

[nikeastwood]

a replacement turbo has come my way from a mate who breaks cars, its from a ford with same engine and bhp. I think its a chinese jobby but its almost new, it was fitted to his own car and the gearbox went, so he just stripped it. I got the ex. manifold too.

I have taken my old one back off today, I am awaiting a piece of copper to make a new sealing gasket with, in the meantime I wanted to check the turbo oil feed for flow, is there a fuse I can pull that enable me to turn the engine over without it trying to fire?

or do I need to just unplug all of the injectors?

[white exec]

Copper gasket a good idea, 1mm+. It should anneal/soften itself with normal use, so retighten after first using.
Use a thin coating of LiquiMoly exhaust sealant (Auspuffpast - I kid you not) on both sides of it.
Brass double-height nuts a good idea to head off future seizures.

[nikeastwood]

this is the gasket I want to renew, the copper turned up by courier this evening

will get two gaskets out of it if I am careful

its 1.2mm thick

I also have some alloy same thickness, but an gonna try the copper first.

[nikeastwood]

all sorted, was quite easy to make a new gasket once the holes were marked up and drilled, I used a hole saw for the large one.

all back together with this used turbo, and I have changed the oil and - not had this car long and I bought it cheap with problems, one of which was oil coming from all over, each time I have fixed something leaking its been cleaned and run up to temp and then see if anything drips off the bottom of the engine, its all stopped now.

diy gasket on right

[white exec]

Hopefully another job ticked off!

[nikeastwood]

well, just one query

upon cold start, there is a puff of smoke from the dpf to turbo joint, the v band clamp doesnt go all the way round the joint leaving around 20mm unclamped - I will get a pic tomorrow

I undone it slightly today and moved it round a bit which seemed to be better.

should the v band clamp go all the way round the joint, they all look like there is a gap and some clamps I have seen look to have a larger unclamped area than mine.

I did seat this top joint first, then the two mid way 13mm nuts to the block [actually could only reach one, gearbox side of dpf] none of these nuts were fitted when I first did the job in my opening post. and finally the clamp to exhaust pipe last.

I will get image tomorrow, and possibly a video of its first start.

can a smear of paste be put into the joint if I get it apart again?

[white exec]

The V-clips don't usually go all the way round. If a small gap, try adding some exhaust paste (Holts FireGum used to be good, or the LiquiMoly same) in decent thickness.

[citroenxm]

if its a pre 2010 hdi 90bhp it wont have a DPF, i think thy just have a CAT.. .we have a 207 hdi 90bhp, on a 2009. I have to say its been amazing. We bought it on 125k, we are now on 188k. Original turbo. oil changes at 12500 miles, and at each service check injector clamps, which have never come loose, either we have been lucky or just done things correctly, the car has only had a front spring, full set of brakes inc cylinders, oil cooler because of an oil leak, and set of injectors because it developed a miss when cold. looking on 207 fb pages id be scared to buy a 207 with all the issues I read about. Me though, I love the 207s very much the SW is a great size..

How has the chineese turbo held up??

[nikeastwood]

How has the chineese turbo held up??

well, I have put the car on some temp insurance for today and am giving it a run because I havent driven it on the road since I got the car a few weeks ago due to quite a few faults being sorted, a run of 50 miles on the motorway home from the seller and the car could only do an indicated 30mpg, I have been and put some fuel in just now and all seems well at the moment and right away the mpg is in the high 40's

turbo seems very hot though, and its smoking off any oil drips from when it was put in, the whole engine seems very hot although the temp gauges show it to be normal.


a brief history of faults were, it had a potentially blocked dpf and depollution faults, the MAF was faulty, and also the IAC [which might be inside the maf?], the air filter was like a block of coal no idea when that was last changed! , the turbo air outlet pipe to IC was leaking, the last time the diesel filter was changed was possibly 2012 [that was the date on it] all of those things meant engine was running rich and poorly and easy to block a DPF like that, all sorted and a new dpf fitted, new filters, air oil and diesel and new oil the other day. There were a few other fault codes but they have been sorted, except I still have an "Open circuit" on the fuel cap sensor, I have not been underneath that corner yet to find where the plug for its loom goes, it might just be unplugged, but using diagbox the additive pump runs [no idea on actual additive level]. there were a few other things like this, two cables in the boot were unplugged, a "diesel heater" fuse was missing in engine bay, Externally and inside the car seems well looked after [there was 207oc sticker in back window - owners club?], but I think the engine has been neglected either out of cost or cba'ness. Its last owner just used it for college for the last 3 years just a couple of miles away from his home. that also will not do the dpf much good. The tracking needs some slight adjustment and the brakes feel a bit soft but these will be sorted soon. Due to the date on the diesel filter, I feared for the condition of the cam belt, so a pug specialist is doing that for me next week, new belt etc, water pump, etc etc, new coolant, I am capable of doing it myself but I just dont want to.

[white exec]

That's a lot of stuff to catch up on, but good that you're doing it, and methodically.
The engines are basically tough, and while performance might have dropped off (neglect and too many short journeys), it ought to come back.
When you can, put in some decent (main brand) fuel, as well as a remedial (200:1) dose of diesel system cleaner (Wynn's, Millers, or 3CV) to clean up the pump and injectors.
Get the coolant replaced too, when the w/pump is being done.

[citroenxm]

Our 2009 1.6 hdi pre dpf 90bhp sw 207 manages average 60mpg with ac on all the time. And it does do about that too.. Not a fuel computer blip