1.6 Hdi / DV4 / DV6 turbo feed modification.

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Re: 1.6 Hdi / DV4 / DV6 turbo feed modification.

Post by GiveMeABreak »

Pappi wrote: 26 Apr 2019, 18:00 Hi guys. Bumping this thread. I've just baught a 407 1,6HDI with only 88000 miles on it. I got it really, really cheap.

I want to remove the wire mesh filter on it. Do you know if there is a step by step instruction or video anywhere?

The car runs fine and I do not have any lack of power, but in my opinion the turbo has a slightly too loud whining noise. So I'll change the oil and remove the wire mesh filter. But I'll need guidance from a guide or something to do it...
Are you after the procedure to replace the Turbo Banjo Bolt with the later modified one that has a removable strainer?
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Re: 1.6 Hdi / DV4 / DV6 turbo feed modification.

Post by Pappi »

GiveMeABreak wrote: 26 Apr 2019, 18:52 Are you after the procedure to replace the Turbo Banjo Bolt with the later modified one that has a removable strainer?


I'm thinking of leaving it without a strainer completely. Bad idea? The car is a 2007, nice condition, but the turbo whining made me a bit uncomfortable. Some service bulletins had instructions to remove the filter completely if I'm not totally misinformed.
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Re: 1.6 Hdi / DV4 / DV6 turbo feed modification.

Post by Pappi »

Is it true that this absolutely requires me to take down the dpf and exhaust to get to the bongo thing? No way to do this without having to lift the car? The place I usually go to when I need to lift cars charges about 0.3 euros a minute for the spot...
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Re: 1.6 Hdi / DV4 / DV6 turbo feed modification.

Post by GiveMeABreak »

Not that I can see - but there was a modification as I said in the official notes the bolt with a new design that has both a larger and removable filter. So at least it can be cleaned out regularly. You could end up with a lump of crud blasting through the turbo if not careful and that is expensive.

I'll put the procedure up here anyway in case you decide to replace it (unless the modification has already been done of course).
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Re: 1.6 Hdi / DV4 / DV6 turbo feed modification.

Post by GiveMeABreak »

Engines concerned:
  • DV4 engines all types
  • DV6 engines all types
Application: Immediate.

Modification
Replacement of the lower banjo bolt on the turbocharger lubricating pipe with a banjo bolt that has a removable, larger-capacity, strainer filter.

Previous Assembly
Banjo A.PNG
"a" Integral strainer filter.
(1) Turbocharger lubricating pipe.
(2) Banjo bolt with integral strainer filter.
(3) Seals.

New Assembly
Banjo B.PNG
(4) Banjo bolt.
(5) Seals.
(6) Removable strainer filter.

Repair
Previous assembly
If removing the turbocharger, replace the old banjo bolt (2) with the new banjo bolt (4) fitted with the removable strainer filter (6).

Refit:
  • The banjo bolt (4) fitted with the strainer filter (6)
  • The seals (5) (new)
New assembly
If removing the turbocharger, check the condition of the strainer filter (6).
If the removable strainer filter (6) is clogged, replace the assembly of bolt (4) and removable strainer filter (6).

Refit:
  • The banjo bolt (4) fitted with the strainer filter (6)
  • The seals (5) (new)
Only the new parts are supplied by PSA post this Modification
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Re: 1.6 Hdi / DV4 / DV6 turbo feed modification.

Post by Pappi »

Okey, yeah that sounds not so good. Better replace it with the new type of bolt then.

I don't think it's done, the car is self-serviced a lot besides the timing belt and water pump change. I know the oil quality is even more important on this engine, wrong oil or semi-synthetic is a disaster to use on this one. I would not be surprised if it's been used some time in it's life. The dpf is renewed and eolys topped up. Runs well and no fault codes. But loud turbo whine. Suspecting blocked strainer.

Thanks for the instructions Marc. I'm wondering if it's easier to remove the whole turbo or to remove dpf/exhaust and tackle it from there. I not so keen on lifting the car, because of the rent cost in my local shop.
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Re: 1.6 Hdi / DV4 / DV6 turbo feed modification.

Post by Pappi »

I just realised that was a stupid questions since I will need to lift the car to get to the lower banjo. Sorry guys, it's been a long day and haggling. Seems I have no option other than removing the dpf/exhaust for this.
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Re: 1.6 Hdi / DV4 / DV6 turbo feed modification.

Post by GiveMeABreak »

Yes the DPF and catalyst is required to be removed as part of the turbo removal and refitting guide. I think this is where the confusion comes from on other Forums / the Web about removing the filter - because, as part of the removal and refitting it does ask to check if there is a strainer there and to remove it. What people won't realise is that the modification procedure would be read by a technician in the workshop when doing the turbo - so the removal is a reminder to take the old assembly off and replace with the new modified part.

I think it is a case of only half the information again.

Anyway, if you want the turbo removal refitting guide let me know, but I won't put it up unnecessarily as it's a lot to type up unless you are doing the job yourself.
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Re: 1.6 Hdi / DV4 / DV6 turbo feed modification.

Post by Pappi »

I am doing this job myself. Do I really need to remove the entire turbo to replace the lower banjo? Can't I just remove the bolt and change it, with the turbo in place? Having a hard time finding the new bolt/strainer, from a trusted shop...
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Re: 1.6 Hdi / DV4 / DV6 turbo feed modification.

Post by GiveMeABreak »

It's the lower banjo bolt that has the modified design, so I can't say if you can access it or not on your vehicle. It is shown as Part 5 on the diagram below:
Banjo D.PNG
This chap has done a video on a Picasso with the same engine where the turbo bolt holding the vanes on came off! This caused the turbo to whine - you can see the damage it caused. It may be useful in showing you what he took off and how to get to the various parts:

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Re: 1.6 Hdi / DV4 / DV6 turbo feed modification.

Post by Pappi »

Thanks Marc you're a star!
Holy s*it that turbo was mess. I'm going to check the turbo first thing tomorrow, if there is any play in it or so. Mine has no lack of power or any smoke, yet, so I hope my nut is still where it should be.

I saw that you can loosen the top oil feed banjo on the turbo and let the car idle for a minute to see it feeds oil or not. But I'm not sure, don't know how much oil it should pump or anything.

I'm going to have a ton of work on this car, but for the price I got it and due to the low mileage it's absolutely worth it. Even if I need to replace the turbo.
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Re: 1.6 Hdi / DV4 / DV6 turbo feed modification.

Post by GiveMeABreak »

I believe the replacement bolt with strainer was replaced from 24th October 2005 (RPO 10577), but as I don't have your VIN for the 406 - I'm guessing it has the new part being a 2007 model. Fingers crossed.
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Re: 1.6 Hdi / DV4 / DV6 turbo feed modification.

Post by Pappi »

GiveMeABreak wrote: 27 Apr 2019, 02:02 I believe the replacement bolt with strainer was replaced from 24th October 2005 (RPO 10577), but as I don't have your VIN for the 406 - I'm guessing it has the new part being a 2007 model. Fingers crossed.


I thought it was 2009 they replaced it?

Anyway, my VIN is VF3**************[VIN obfuscated, can be read by forum staff]
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Re: 1.6 Hdi / DV4 / DV6 turbo feed modification.

Post by Pappi »

Does anyone know for sure what year the banjo bolt was "upgraded"? Would be nice to know, instead of having to take the cat/dpf and exhaust down to check if it's the new or old on my car.
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Re: 1.6 Hdi / DV4 / DV6 turbo feed modification.

Post by GiveMeABreak »

There's no date on the modification info - but the part was replaced from the date I mentioned in my last post.

Basically the reason some people remove the filter is because on higher mileage cars, especially where the servicing has not been kept up, or where the oil has not been changed at shorter intervals than recommended, there can be debris and oil contamination in the oil that can block the small filter in the banjo bolt, causing oil starvation to the turbo.

So it is probably a matter for each owner to decide.

I know that Garret recommend removing the filter for this reason on higher mileage cars. They have a video on it here: 6:28 is the time index where they show this:



Here's a picture of the modified bolt - you can see the plastic filter in the end:
Banjo Bolt.PNG
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