Description

This product is a reconditioned Mitsubishi TD02 turbocharger, specifically designed for the Citroen Berlingo 1.6 HDi with the 9HX (DV6B) engine, producing 75 HP, manufactured between 2006 and 2008. It directly replaces original equipment part numbers 49173-07508 and 9682881780. Our reconditioned units offer a reliable and cost-effective solution for turbocharger replacement.

Common failure modes for this TD02 unit on the 1.6 HDi engine often include issues with the actuator diaphragm, leading to incorrect boost pressure regulation, or internal oil seal degradation, resulting in oil consumption and blue smoke. Wheel damage, typically caused by foreign object ingress or excessive shaft play due to inadequate lubrication, is also a frequent occurrence. These issues can manifest as a loss of power, excessive smoke from the exhaust, or unusual noises from the turbocharger itself. We strongly recommend identifying the root cause of the original turbocharger failure before fitting a replacement to prevent repeat issues.

What this turbocharger fits

This reconditioned turbocharger is a direct fit for:

• Vehicle: Citroen Berlingo
• Engine: 1.6 HDi (9HX / DV6B)
• Power Output: 75 HP
• Year Range: 2006, 2007, 2008
• Original Part Numbers: 49173-07508, 9682881780

At Gap Turbos, our reconditioning process for this TD02 unit involves a complete strip-down, thorough cleaning, and inspection of all components. The core assembly is meticulously rebuilt, with critical wear parts such as bearings, thrust collars, and oil seals replaced with new, high-quality equivalents. The actuator diaphragm, a common failure point, is also renewed. Both the compressor and turbine wheels undergo precise balancing to OEM specifications, and the entire CHRA (Centre Housing Rotating Assembly) is tested for oil pressure and shaft stability. Finally, the complete turbocharger is dynamically balanced and calibrated on a VSR machine to ensure optimal performance and longevity, meeting or exceeding original manufacturer standards. We pride ourselves on delivering a reliable, cost-effective alternative to a new unit. We also offer new exchange units for certain applications, fitment services in our Birmingham workshop, and comprehensive DPF/catalytic converter cleaning to address underlying issues that can contribute to turbocharger failure.

For a precise quote and details on our warranty, please contact Gap Turbos directly. Our reconditioned units come with a standard 12-month warranty, subject to correct fitment procedures and addressing the root cause of failure.

Specifications

Vehicle fitment

• Citroen Berlingo 1.6 HDi

Common faults & troubleshooting

[‘* Loss of power or sluggish acceleration: Often indicates an issue with boost pressure, possibly due to a failing actuator diaphragm or boost leak in the intake system.’, ‘* Excessive blue/grey smoke from exhaust: Suggests oil is entering the exhaust system, typically from worn turbocharger oil seals or excessive crankcase pressure.’, ‘* Whining or whistling noise from the engine bay: Can be a sign of worn turbocharger bearings or contact between the compressor/turbine wheel and its housing.’, ‘* Oil leaks around the turbocharger housing: Points to failed oil seals or loose connections in the oil feed/drain lines.’, ‘* Check Engine Light (CEL) with P0299 (Underboost) code: Directly indicates the turbocharger is not producing the expected boost pressure, often an actuator or wastegate issue.’]

Fitting notes for this unit

[‘* Oil Feed Pipe Replacement: Always replace the oil feed pipe to the turbocharger and thoroughly clean the banjo bolt filters, as blockages are a primary cause of TD02 failure on DV6B engines.’, ‘* Sump & Strainer: Remove the sump, clean it thoroughly, and replace the oil strainer to eliminate any carbon deposits or debris that could restrict oil flow.’, ‘* Oil & Filter Change: Perform a full engine oil and filter change using the manufacturer-specified grade and volume of oil, ensuring the system is free of contaminants.’, ‘* Prime the Turbo: Before the first start, disconnect the fuel system or spark plugs (if applicable) and crank the engine for 10-15 seconds to allow oil pressure to build and prime the turbocharger.’, ‘* Gasket Replacement: Always use new gaskets for the turbocharger mounting flange, oil drain, and exhaust connections to ensure a leak-free seal.’, ‘* Torque Settings: Adhere strictly to manufacturer torque specifications for all turbocharger mounting bolts, especially the oil feed banjo bolts, to prevent leaks or damage.’]

Alternative part numbers

This turbo is also referenced by:

• 9682881780 — Citroen Turbocharger OEM 9682881780 (Citroen Berlingo 1.6 HDi, 9HX (DV6B), 75hp)

Frequently asked questions