Turbo Replacement - Ford 1.6 TDCI

[XperiAnce]

Hi All.

Had an Engine Warning light go off and around a 30% loss in power. No smoke or noise, just loss of power.

Took it to Ford, being quoted the below. Hoping for suggestions if all repairs needed, cheaper alternatives (did phone a few places but no commitments to prices) and recommended course of action.

Engine - Other
Egr valve replacement
R7937.36
Engine - Other
Intake manifold replacement
R15846.80
Engine - Other
Turbo replacement
R5848.20

 

[ToxicBunny]

Is the vehicle under warranty or not?

 

[XperiAnce]

Nothing, this would be a pure cash repair.

 

[Pitbull]

Hi All.

Had an Engine Warning light go off and around a 30% loss in power. No smoke or noise, just loss of power.

Took it to Ford, being quoted the below. Hoping for suggestions if all repairs needed, cheaper alternatives (did phone a few places but no commitments to prices) and recommended course of action.

Engine - Other
Egr valve replacement
R7937.36
Engine - Other
Intake manifold replacement
R15846.80
Engine - Other
Turbo replacement
R5848.20

Why this?

If the turbo goes why do they have to replace in manifold?

 

[Beachless]

Looks like you are being shafted big time.

 

[HunterGR]

you could probably get a recon motor for that amount of money

 

[PsYTraNc3]

Sheesh... Definitely getting rid of my car before the warranty expires.

 

[XperiAnce]

Why this?

If the turbo goes why do they have to replace in manifold?

Am also curious about that. Will get better details as to why from Ford.

 

[saturnz]

Is there a diagnostic on whats the problem?

I can't see why replacing a turbo will solve the problem. Even if a turbo smokes you won't lose 30% power, it basically has to break the shaft for there to be a loss of significant power.

 

[Ancalagon]

Get a second opinion. Find an independent garage, and take your car to them.

Don't give them the Ford quote or even tell them what Ford says. Don't even mention the turbo.

Just take it to them, describe what happened, and that there is a problem.

 

[XperiAnce]

Am also curious about that. Will get better details as to why from Ford.

Apparently carbon pieces clearly in the Intake Manifold as well as inside the turbo.

 

[Beachless]

Is there a diagnostic on whats the problem?

I can't see why replacing a turbo will solve the problem. Even if a turbo smokes you won't lose 30% power, it basically has to break the shaft for there to be a loss of significant power.

The loss of power will be due to the enging going into limp mode.

My guess is that they are just replacing stuff at random and hoping it fixes the error codes they are getting they actually have no idea whats wrong with he car.

 

[Beachless]

Apparently carbon pieces clearly in the Intake Manifold as well as inside the turbo.

Then clean out the carbon with an acid bath?

 

[saturnz]

The loss of power will be due to the enging going into limp mode.

My guess is that they are just replacing stuff at random and hoping it fixes the error codes they are getting they actually have no idea whats wrong with he car.

I agree, they should always give you a diagnostic upfront, and if they can't give you a diagnostic then what exactly are they doing?

 

[silent_wolf]

The loss of power will be due to the enging going into limp mode.

My guess is that they are just replacing stuff at random and hoping it fixes the error codes they are getting they actually have no idea whats wrong with he car.

Thats basically what audi does.

As said get a 2nd opinion, also if I'm not mistaken you can probably acid dip the intake manifold to remove the carbon

 

[Colin62]

Am also curious about that. Will get better details as to why from Ford.

It looks like your EGR (Exhaust Gas Recirculation) valve has become clogged up. This usually happens if you spend a fair amount of time sitting in traffic. The EGR takes exhaust gas and pushes it back into the inlet manifold in an attempt to reduce exhaust emissions to meet EU regulations. If you're doing a lot of stop start driving, both the EGR valve and inlet manifold clog up with gunge to the point where you start to use more fuel and lose power. Often it can be cleaned, but that gunge is bloody stubborn, and the agents will just replace.

I'd do some research into removing the EGR. It's not needed for normal running, and we don't have the EU regulations to comply with. The problem with pulling it out is that it provides feedback to the ECU and you need a system to fake that if you're removing it. I know the fix for Merc diesels, and maybe you can find something similar on the Ford forums somewhere.

At the very least I'd consider taking it to an independent mechanic (but who specialises in Ford and knows diesels). They might well be prepared to clean it out rather than replace. Down side is that your labour costs will go up.

I'd also get the EGR and manifold tidied up before I replace the turbo - it's entirely possible that it'll be working once it's got a clear path to push the air down.

 

[XperiAnce]

Do you have any recommendations for people who offer services mentioned above?

I've phoned a few places but none really keen on helping such a broad problem.

Guy at Ford said, basically, the below:

EGR Valve gone. Carbon pieces / elements present in Intake Manifold as well as in Turbo. EGR valve can be replaced alone, however damage to Turbo needs attention and carbon elements inside the intake manifold might cause problems further down the line.

 

[Colin62]

Do you have any recommendations for people who offer services mentioned above?

Sorry, no clue there. Ford owners forum might help?

 

[Spliffcat]

Stealer is shafting you badly.

Edit: If turbo gone you will have no power. Limp mode. Blank off EGR.
Join the 4x4 Community Forum. Huge amount of knowledge there.

 

[saturnz]

It looks like your EGR (Exhaust Gas Recirculation) valve has become clogged up. This usually happens if you spend a fair amount of time sitting in traffic. The EGR takes exhaust gas and pushes it back into the inlet manifold in an attempt to reduce exhaust emissions to meet EU regulations. If you're doing a lot of stop start driving, both the EGR valve and inlet manifold clog up with gunge to the point where you start to use more fuel and lose power. Often it can be cleaned, but that gunge is bloody stubborn, and the agents will just replace.

I'd do some research into removing the EGR. It's not needed for normal running, and we don't have the EU regulations to comply with. The problem with pulling it out is that it provides feedback to the ECU and you need a system to fake that if you're removing it. I know the fix for Merc diesels, and maybe you can find something similar on the Ford forums somewhere.

At the very least I'd consider taking it to an independent mechanic (but who specialises in Ford and knows diesels). They might well be prepared to clean it out rather than replace. Down side is that your labour costs will go up.

I'd also get the EGR and manifold tidied up before I replace the turbo - it's entirely possible that it'll be working once it's got a clear path to push the air down.

I'm not an EGR expert but it seems to me that you should bypass the EGR valve as it serves no performance purpose, except to preserve trees, not when the turbo is already forcing air into the intake. I'm sure aftermarket solutions exist for getting pass the management.