Oil catch can time.

[Huskyxantia]

So, owning this little 206cc I've learnt a lot fr0m it, its time now to make an oil catch can , as its sucking through to much oil and blowing through the turbo and out the exhaust .

Will this effect the emissions ?

[MattBLancs]

The round lump on top of the plastic cam cover contains a diaphragm / valve - on my wife's DV6 (1.6) HDi 206, this diaphragm was split. The cover will pop off with gentle prising of each of the plastic clips around its perimeter. It's not listed as a separate part in PSA terms, but I found a seller online selling replacement diaphragms. I think a split diaphragm has a negative effect on the amount of oil carried over. The plastic cam cover also has a baffle arrangement internally, giving a tortuous route for the oil laden gases. I gave this a good clean out (when doing a partial top end refurb / refresh / clean out when it was on the edge of turbo failure)

Matt

[MattBLancs]

Not the one I bought (am sure was black plastic, included no new spring or cap either) but below is an example of what I mean:

https://www.ebay.co.uk/itm/203848318677

Matt

[Huskyxantia]

Many thanks i, going to give that a try first i hand a niggle it may of been that, cheers again.

[Huskyxantia]

Ok, the diaphragm is intact but hard the spring was gunked a bit , a new one is on its way and cap as they do tend to snap the clips, £11 non chinese too.

[MattBLancs]

Similar to my experience (spring light coating of oily black gunk, diaphragm hard (though also split in my case))

I did get my original cap off without damage, but for £11 including a cap saves the need for a delicate approach!

Hope that sorts it.

Side note: I also changed the O-ring in the connection between cam cover and inlet pipe - my oily mess wasn't confined to inside the pipe only, was external and all over the vacuum pump below too.

Matt

[Huskyxantia]

I've recently got a replacement pipe with the o ring i must say it isnt lining up so im going to put the original back on and use the o ring that came with the new one, see if that helps as ive noticed oil in the same place you mentioned, also the pipe work has oil inside, which is passing through the turbo when you give it gas it does smoke not for long , ive been looking at turbos a couple of hundred quid new, gonna see when the diaphragm is done and the original pipe is put back if that makes any difference, as with this new pipe is when i did notice more oil spilling onto vacuum pump , the 307 2.0hdi did modified this set up and it looks like it sorted a lot of problems

[MattBLancs]

I wouldn't think a bit of oil in the intake pipework would be significant enough to give you smoke on acceleration in my experience.

It is normal to see some oil after the PCV connection, it's dependent on how good the separator is at filtering out the little particles of oil carried by the gasses. In my experience all factory oil separator attempts work poorly!

O-ring: I swapped in a new one from a selection box. (From Aldi, it was one of their "yes of course we can have this obscure engineering hardware as a special buy" ranges! See also aviation snips and many other things I've snapped up from them!)
Anyway, source is irrelevant, point is it's a bit chunkier section than the standard one, and that seems to have made the difference to it escaping from the pipework.

1.6 DV6 has a reputation for eating turbos. Not sure how good the cheap ones online are. It's a complex thing a turbo, doing tens of thousands of rpm , and hence balanced to a tight tolerance. I.e. not easy to make that cheaply!?

Have you done the "turbo shaft wobble test" ?
Up and down (radial) movement, within reason, is ok. But any movement along the shaft (axial) is bad news.

A puff of smoke when giving it some welly could be a number of things, EGR not closing (should be completely shut under hard acceleration. Partly open = less oxygen so engine runs rich = smoke) tends to have noticeable impact on performance and likely throw a code too.

Think I've read you've only recently got this, so a previous owner who never gave it some welly would leave plenty of spot in the exhaust waiting for a good blast of high revs to dislodge it (not sure that's the case in the world of DPF equipped cars??)

Incidentally, that's another question: is the DPF still present and/or is it likely to have a less than perfect remap?

Matt

[Huskyxantia]

Dpf was new last June , but wasnt really used till this year, i do get fault codes on pp2000 about the egr claiming to be stuck , thing is it runs real good plenty of power starts first turn

[Huskyxantia]

Not sure if its legal to remove a dpf or egr now

[Huskyxantia]

I wouldn't think a bit of oil in the intake pipework would be significant enough to give you smoke on acceleration in my experience.

It is normal to see some oil after the PCV connection, it's dependent on how good the separator is at filtering out the little particles of oil carried by the gasses. In my experience all factory oil separator attempts work poorly!

O-ring: I swapped in a new one from a selection box. (From Aldi, it was one of their "yes of course we can have this obscure engineering hardware as a special buy" ranges! See also aviation snips and many other things I've snapped up from them!)
Anyway, source is irrelevant, point is it's a bit chunkier section than the standard one, and that seems to have made the difference to it escaping from the pipework.

1.6 DV6 has a reputation for eating turbos. Not sure how good the cheap ones online are. It's a complex thing a turbo, doing tens of thousands of rpm , and hence balanced to a tight tolerance. I.e. not easy to make that cheaply!?

Have you done the "turbo shaft wobble test" ?
Up and down (radial) movement, within reason, is ok. But any movement along the shaft (axial) is bad news.

A puff of smoke when giving it some welly could be a number of things, EGR not closing (should be completely shut under hard acceleration. Partly open = less oxygen so engine runs rich = smoke) tends to have noticeable impact on performance and likely throw a code too.

Think I've read you've only recently got this, so a previous owner who never gave it some welly would leave plenty of spot in the exhaust waiting for a good blast of high revs to dislodge it (not sure that's the case in the world of DPF equipped cars??)

Incidentally, that's another question: is the DPF still present and/or is it likely to have a less than perfect remap?

Matt

When the work was being done last year the chap helping did test the turbo so have i he said it was all good , to me it felt normal , it had movement but little none to make the cartridge knock, ive just remembered when you drive the car makes little whooshing sounds it happens when you push the gas pedal down a touch and also when you come off the gas , if you drive slow as i do out of my village its like that Knight rider sound people have asked how ive got the sound you know the younger lads and i say its just what it does , is this normal ?
The vacuum pipe off the turbo solenoid did have some pin holes so ive changed that havnt drove it yet as im waiting for the other bit, were having post strikes at the mo, so i will have to up date this after ive done the pvc valve thing and taken it for a run., thanks for your input its great.

[myglaren]

Not sure if its legal to remove a dpf or egr now

Definitely not.

When the work was being done last year the chap helping did test the turbo so have i he said it was all good , to me it felt normal , it had movement but little none to make the cartridge knock, ive just remembered when you drive the car makes little whooshing sounds it happens when you push the gas pedal down a touch and also when you come off the gas , if you drive slow as i do out of my village its like that Knight rider sound people have asked how ive got the sound you know the younger lads and i say its just what it does , is this normal ?
The vacuum pipe off the turbo solenoid did have some pin holes so ive changed that havnt drove it yet as im waiting for the other bit, were having post strikes at the mo, so i will have to up date this after ive done the pvc valve thing and taken it for a run., thanks for your input its great.

Lad across the road has an old BMW, imported from Poland, that does that.
There was also a Seat Leon further up the road that did it to the extreme, could be heard several streets away although the engine was quiet.
I presumed that it was a dump valve.

[MattBLancs]

If does it on as well as off the gas then I'd think it's a not very well set up dump valve if present! (I.e. if it's bleeding off boost when you are supposed to be making power then that's not helping)

What's the exhaust like? (Silencer at rear only on my wife's 206, which is a GTi Hdi - not sure if were more silencers on the non-gti flavour? Incidentally that silencer has been replaced with a straight piece of pipe on this one. Made negligible difference to its sound.
DPF still present and correct here.

As said, not legal to remove it anymore. I'd have thought no DPF and no silencers could also give audible turbo noises.

Suppose other question is is there an air filter in the housing, could hear the turbo through the relatively short intake pipework.

Just thinking aloud really,

Interesting from your pictures your DPF and catalyst is one piece unit, this has a two piece item, great big band clamp around the middle. Not sure if that means you've a replacement unit there or it changed between (2004) mine and 2006 (yours)

Matt

[Huskyxantia]

Yeah the dpf is a replacement I've still got the original which i did pressure wash last summer , it wasn't to dirty to be honest , pondering on putting that back on with its big massive clip lol and wondering if this might make a difference to any egr faults if they pop back up again ?
Air filter is new and in its box, the whoosh sound isn't loud like them fake stupid turbo kits things from ebay.. whooooshhhh .. but if your next to the car it can be heard steady build when taking off steady drop when slowing down, plus the power is still there, my 307 2.0hdi you can hear a similar sound ,non turbo, so it may be the air going through the system ? Very gentle whistle very very soft. Rear box its gti spec as what the seller said as it shares stuff like body parts and so on , oh and the back box is about a yr old too. Plus i did the solid fly wheel conversion when the clutch was done last yr, thought it would be better than a dual mass one, only down side is the rumble sound , it was put in with the proper alignment tool, i was told and have read the solid ones do make a noise but last a lot longer than dual mass types.

[MattBLancs]

There is lots of debate about the pros and cons of the single mass flywheel conversion. They exist because the torque pulses particularly in a modern diesel engine are tough on the gearbox. The DMF smoothes these pulses and gives the gearbox an easier time.

The springs in a conventional (single mass flywheel) clutch also absorb these pulse to a lesser extent. (A DMF clutch= no springs)

So the risk is you have an everlasting (single mass) flywheel but a short lived gearbox...

This one went, put in a new DMF. Yes £3-400 buys a good number of second hand BE4 gearboxes, but happier to keep with the standard setup.

I had a go cleaning out the DPF too. Couldn't get much from it either. Having had a watch on YouTube of professional DMF cleaning and I think it's something we cannot easily recreate at home. Massive pressurised flow of water, high volume flow rate as well as pressure, forces flow across full face of the filter.

Matt