how to replace 1.6HDi turbo (90bhp); M59

[saskak]

Hi all,

In case of interest, here is how I replaced the turbo in my 2007 1.6HDi Peugeot Partner (a badge difference; M59; 9HXC engine; DV6ATED4). Well, not the whole turbo, just the cartridge with the associated oil feed and return. The old turbo had not failed, so there was no need to replace the rest, e.g. the turbo housing.

I made of few videos of the procedure, which you can find here (5 videos in total, ~2h footage).

1/5 access and removing the old turbo: https://www.youtube.com/watch?v=Q7S0qDBo314
2/5 replacing the turbo cartridge with Nerings cartridge: https://www.youtube.com/watch?v=Q30w90Vcs7U
3/5 fitting the new turbo: https://www.youtube.com/watch?v=QHY_uPbPfyg
4/5 assemble everything back together: https://www.youtube.com/watch?v=l2A0_AV9OH0
5/5 running the engine again: https://www.youtube.com/watch?v=wHnC8wPi0Qc

I also replaced the sump with a new one. I did not replace the oil pickup, as it was really clean. The old banjo bolt was spotless and I replaced this with Nerings' 1.6HDi turbo replacement kit that included the oil feed, return, new banjo bolts (new design longer filter inside). To my surprise, the sump was rather clean, no bits, nothing.

Overall, it was relatively easy to do, about 4 days of work, mainly removing parts to get access. The new turbo is smoother in pickup (could be a placebo effect) and I have driven it for the last 3 months without any problems.

Cheers,
saskak

[Tomcat3]

Nice one saskak this will help others sort the turbo issue out not fill them with dread and huge bills.

[saskak]

Nice one saskak this will help others sort the turbo issue out not fill them with dread and huge bills.

It was easier than I thought, although I bought the cheapest turbo on ebay and had a test on that beforehand, although it was not needed. Otherwise, rough cost estimate, the cartridge is £80, the banjo bolts, oil feed/return in the Nerings kit was £70 (includes oil sump pickup). On top is the new oil and filter, WD-40 etc. All in all, can be done for <£200. I also did the sump (~£40) + sealant. I would say £250 covers everything, apart from the time of course.