1.6 HDi / TDCi turbo fitting guide.
Fitted to Peugeot 207/307/308/3008, Citroen C3/C4, Ford Focus/Fiesta/C-Max. Common failure, real time estimate, torque specs.
40
Years of workshop time
24
Month warranty, transferable
49
UK cities covered
9
In 10 DPFs cleaned, not replaced
The 1.6 HDi/TDCi (PSA DV6TED4, Ford T1DA/T3DA) is the most common turbo we rebuild. The failure pattern is oil starvation on the CHRA from a partially blocked feed pipe. Symptoms are shaft-play whistle, black smoke, and P0234 or P0299 stored fault. The recon plus a new feed pipe fixes it 9 times out of 10. We ship next-day.
Symptoms and diagnostic codes
- Whistling on acceleration, especially cold: shaft-play, needs recon.
- Blue-black smoke on load: seal failure, needs recon.
- Fault codes:
P0234(overboost),P0299(underboost),P132B(turbo control). - Power drop to limp mode above 2,000 rpm: stuck VNT actuator.
- Oil in the intercooler pipe: seal or bearing failure.
Fitting procedure
- Disconnect battery, remove engine cover and airbox. Time: 15 min.
- Remove front lower undertray and front bumper support (Peugeot) or the intercooler (Ford). Time: 30 min.
- Disconnect oil feed and drain pipes, vacuum line to VNT actuator, electrical plug on boost sensor. Time: 15 min.
- Unbolt DPF from turbo outlet, unbolt manifold nuts (M8x1.25). Time: 20 min.
- Withdraw the turbo, transfer heat shield if fitted. Time: 10 min.
- Replace oil feed pipe (mandatory on 3008 and C-Max). Time: 10 min.
- Fit the reconditioned unit with new manifold gaskets, torque nuts to
25 Nm. Time: 30 min. - Reconnect oil pipes, torque banjo bolt to
32 Nm. Prime CHRA by cranking 10 sec with injectors disconnected. Time: 10 min. - Refit ancillaries, road test, clear codes. Time: 30 min.
Total workshop time: 3 hours 15 minutes on the Focus, 3 hours 45 minutes on the Peugeot 3008.
Prices
- Reconditioned turbo (exchange, no surcharge):
£280 to £320 - Fitting kit (gaskets, feed pipe, banjo bolts):
£55 - Fitting labour at an approved workshop:
£180 to £240