Oh dear help me before I lose the will

[406HDi3]

Hi all,
Very quickly without non stop pages of text...

406HDi 90 Estate, 2001. Had an intermittent fault with the oil level sensor for couple of years.

Decided to call main dealers for a price and labour quote. £55+Vat for the part plus 1-2 hrs labour.

Took the car in, job was taking longer than normal because the mechanic couldn't get leverage on the old sensor due to lack of engine bay space above sensor. Was given courtesy car.
Next day, 7.2hrs of labour later, it was removed and new one fitted. Apparently quite a few parts including the sub frame were removed to get the old sensor out. I believe something to do with the inlet manifold too.

Book time 4.6hrs so I was later told.

Drove the car out the dealers after it being road tested, major hissing when the turbo was cutting in and severe lack of power going up steep hills.

Took the car back and found that the inlet manifold shoulder joint to the manifold was severely leaking air through the gasket. Could have only been from them putting this sensor in as it's directly above the sensor. They replaced the gasket, +2hrs labour to do this.

They test drove it.

I left the forecourt again (day 3). Now, high pitch whistle from the turbo. Much louder than before. So much so, driving through town, people are turning around because they can hear the turbo whistle. And I'm only in a 406 estate, not a lambo! Highly embarrassing.

Also to note, you can hear the turbo whistle now on the flat at 60-70mph 'over the radio' with very little pressure on the accelerator, ie I'm not accelerating.

At idle, you can now hear a small whine from the turbo area which does change pitch when you move the air filter box hose (just behind the mass air flow sensor).
Revving the engine up at standstill, you can hear the turbo impeller spin up but like a butterfly sound as it spins back down. Doesn't sound normal.

Obviously the car never went in with any problems except the oil level sensor (which I wish i'd left alone now) and now from the mechanics disturbing the area, all these other problems arisen.

The management there been very helpful and have taken the car back in again. This time I took a mechanic out with me who recognised that the turbo was louder than normal and that at idle the whining noise wasn't normal. He wouldn't commit to what he thought it was except possible another air leak or I suggested possibly something got onto the turbo impeller.

They will now discuss with the original mechanic to find out what exactly was removed as to these problems arisen afterwards.

Can anyone suggest why the turbo is now much much louder than normal and what you think may have happened?

I am concerned that the car is back in their hands because I feel like I could be giving my car a death wish if something now breaks that turbo or some fragments get inside the engine. :-(

Serviced every 6000miles / 6 months. 170k miles on the clock and very well looked after by me.

If anyone can put my mind at ease, will be appreciated.

Thanks.





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[lozz]

Hi. (turbo whistle)
split or loose turbo pipe id guess,
check pipework out make sure its all on nice and tight,.

[406HDi3]

Thanks for the reply. It's back with the dealership since they were the one fitting the sensor, and all this has happened as a result.

Just out of curiosity, could something have got onto the turbo impeller?


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[rwb]

Hi & welcome.

That's outrageous.

I think it's time to start communicating with them in writing; you should not be forking out to support their incompetence.
In particular: they should not have made additional charges to your quote without first seeking your permission.
Furthermore, if you've paid extra for them to take it apart and put it back together then you certainly shouldn't be paying again because they f*cked up putting it back together. They've already admitted that they didn't put it back together right and in doing so created a problem: you shouldn't be paying (for the 2hrs gasket) for them to fix it. (The deal with this sort of thing is normally that you're supposed always to use a new one, but according to your judgment you might get away with refitting the old one. Why not ask them to explain why they re-used an old gasket?)

I suspect they'll be going through the motions asking the computer what's wrong and trying to patch it up...

[406HDi3]

Hi and thanks RWB,

Firstly I must clarify they've only charged me for the 2hrs labour + the sensor. And the management there have been very understanding and on my side so to speak.

But I am starting to get concerned as at some point if they can't rectify these issues, who's going to get the blame and I'm 100% certain my car went to them with absolutely no issues at all except a sporadic oil level sensor.

My car over the years and been extremely well maintained and recently I asked my old mechanic who used to service and look after it if he wouldn't mind popping over to give it his inspection, once I'm told they've fixed it. I asked him because in my mind he's a 'mechanical maestro' and I trust his mechanical mind over anyone. Sadly he's stopped trading and started a new business venture.

As for the gasket. Well a different mechanic was doing that and he thought that they wouldn't have even removed that joint to get to the sensor. But looking at its location they've definitely disturbed the joint, even if it meant loosening it slightly.

I did ask about that gasket and was told it fell apart when they removed it. Thats saying something.

It's only a car I know but it's never missed a beat and is in A1 condition throughout. I've spent the last 3 days with stress and interrupted sleep over it, and in my job, sleep deprivation and fatigue is a no no.

I just hope to god that they fix this high pitch turbo whistle and the idling noise before they start blaming each other (and me), before it comes out with even more issues than when it went in.






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