1.6HDi turbo shield

[Romahomepete]

I have been chasing a "rattle" for ages, it would appear that the turbo shiel is suffereing from metal fatigue and has cracked in a number of places and some of the "ears" that the fixing bolts go through have broken off.  i can remove the small shield but it seams impossible to get the larger front part off even with all the bolts removed.

Advice please

Peter

[Sol]

@saskak is the expert on this Pete, he has an excellent YouTube vid on that subject. Hopefully he can advise too.

Have a look - worth subscribing as well.

https://www.youtube.com/watch?v=ox6EIiIpWOo

[geoff]

A few years back I had the same rattle just before a trip away from home ..... quick solution was to cut a piece of feather edge fencing timber ( I had some to hand ) and wedge it between the engine and the shield.

This worked for a couple of years and although I had intended to sort it in a proper fashion I never got around to it .... it lasted me around 25k miles before I sold the vehicle ( only sold because I wanted to have A/C to keep my old dogs comfy. )

Move on to my current Berlingo and after 6 mths of ownership I had a rattle that sounded familiar - the turbo shield rattle.

I cut another wedge ( couple of munites ) and did the same fix ...... I'm now 2 yrs / 18k miles into this and have replaced the wedge only once.

I keep meaning to buy new shields of course but deep down I just know I won't - got to say generally I'm more than happy to spend on all my vehicles as I usually keep them for many years.

[saskak]

@saskak is the expert on this Pete, he has an excellent YouTube vid on that subject. Hopefully he can advise too.

Have a look - worth subscribing as well.  

https://www.youtube.com/watch?v=ox6EIiIpWOo

Yeah, this heatshield rattle is rather common in the M59, I suspect all of the versions as well, the ears with your normal metal/aluminium fatigue and they just break down. Apart from replacing it and it is rather awkward to replace the big front/bottom and the rear heatshield, you can just put an additional metal thing that can bridge it kind of thing and give it strength. The ears on the top broke on mine twice. First time I bought a new top heatshield and that one also broke within 1-2 years and it was not cheap, ~£30-40 for a very small aluminium piece. Go to B&Q or any other diy store and get a steel metal and drill a few holes in it and bend it to shape and fit it like the video that Zion has posted. Has worked wonders for me and I have not touched this part since the video, ~2 years ago. Also, since I put the metal on the top heatshield, it has not rattled since.

[Romahomepete]

Update
I got the top piece off after removing the pipe from the intercooler to the turbo. One ear missing, and several fatigue cracks. Repaired with some bits of galv sheet steel cut from the back of an old washing machine and some pop rivets. The missing ear on the bottom of the large fron piece was repaired in the same way but in situ. A bit more awkward as my pop riveter has long handles and was awkward to get in. Job done now let's see how long it lasts. There is a new top piece for sale on eBay for £33

Peter

[saskak]

Update
I got the top piece off after removing the pipe from the intercooler to the turbo.  One ear missing, and several fatigue cracks.  Repaired with some bits of galv sheet steel cut from the back of an old washing machine and some pop rivets.  The missing ear on the bottom of the large fron piece was repaired in the same way but in situ.  A bit more awkward as my pop riveter has long handles and was awkward to get in.  Job done now let's see how long it lasts.  There is a new top piece for sale on eBay for £33

Peter

Great job. If I were you I would bridge your "new" steel engine ears with another metal to the bolts that connect to the front shield. That would considerably reduce the stress on the front points where it connects to the engine.

[Romahomepete]

The work I did yesterday was more of a stop gap whilst I work out a better solution, making such a thing out of thin aluminium is a recipe for disaster.

I will update once I have found a better solution

BTW. I thought I had put it in the M59 section

P

[Sol]

Moved to the correct section Pete.