Peugeot 406 Turbo Removal / Refitting ( Petrol )

[niz406]

Well guys,

After many requests for such a thread here it is... no pictures though I'm afraid.... not something I have ever taken pics of lol

Tools: ( from memory )

Ratchet - Torque and normal
Extension bar or Metal hoover pipe... leverage ! ! lol
Sockets - 22mm, 19mm, 18mm,16mm, 15mm, 13mm ( Deep 12 sided ), 10mm, 7mm ( Jubilee clips )
Spanners - 19mm, 18mm, 17mm, 10mm
Allen Key - 4 or 5mm
Number 40 Torx Bit and socket
Balljoint Seperator
Lump hammer

Step 1) Jack up and Remove wheels

Chock the back wheels and jack the front of the car up... place your axle stands at the front of the chassis box section / front runners. When looking under the car you will see the jacking points on the sills then in front a box section... right at the front before the step down, as this is the strongest part.

Lower the splash pan from under the car, 10mm bolts all round... some WILL snap!

Locate the radiator drain tap and Place a short length of garden hose or similar over it... and put a bucket under the car with the hose pointing in to it. Turn the tap and remove the expansion tank cap, there are also two bleed screws... remove these also, one is on top of the thermostat cover and the other is on the heater feed going into the bulkhead.

To drain properly, you will need to remove the top rad hose from the thermpostat housing, undo the thermostat cover and remove the thermostat so the coolant in the engine can escape. Once this has drained completely you can then drain the oil.. always better to do an oil change on a new turbo installation, as you dont want the old crap getting into your new blower and causing you problems.

With the oil and coolant drained.... proceed to step 2:

Step 2) Top Engine work

Remove the air box, disconnect all pipes from and remove the plastic inlet pipe 2 x 10mm + Jubilee on turbo inlet ( undo from under car ), remove the alloy charge pipes 10mm before removing the charge pipe connected directly to the turbo it is important to unscrew the two 10mm bolts holding the water and oil feed pipes to it, this is to avoid damage...

Undo oil feed 17mm and water feed pipes ( Undo at clips and pull hose off ), remove exhaust heat shield 9? x 10mm's there is a bolt at the back of the heat shield... undo the top 2 turbo mounting bolts 13mm deep 12 sided socket.

Once all of these have been completed from the top of the car it is time to get under and work from underneath.... Go to step 3

Step 3) Under car work


Remove front lower drop links balljoints from anti roll bar 19mm spanner and 5mm allen key... I think

Unbolt the front lower wishbone balljoints, 22mm and a balljoint seperator ( in some cases a lump hammer too ) with the ball joints and drop links disconnected it's now time to unbolt the steering rack... 2 x 18mm bolts. With these removed you now need to remove the lower torque reaction link, an 18mm bolt that connects the lower part to the subframe... ( depending on the condition of your engine mounts you may need a jack / hoist or brace to take the weight of the engine )

Place a jack under the middle of the subframe and take the weight of the subframe to the point where the jack starts to lift the car, Remove the 4 18mm subframe mounting bolts and then slowly lower the jack and subframe... with the subframe out of the way, it is now easier to access the turbo and assoicated parts for removal... trust me I have done it enough times ! lol

Unbolt the exhaust 2 x 10mm and turbo support bracket, these are allen key bolts but if you don't have them a Number 40 Torx bit works just as well, it will be a fiddle to negotiate the right hand part of the bracket out from the actuator rod, but it does come off..

Next remove the water return 18mm I Think, and oil return 2 x Number 40 Torx... with this removed you can now get the turbo off by undoing the remaining 2 x 13mm 12 sided deep socket and lowering the turbo from the car.. it's best of you have someone to help with this bit so you don't drop it on your head whilst undoing the retaining nuts..

Retain the sealing ring from the turbo / manifold if it falls off as you will need to put this back in when fitting your new / serviced turbo..

Refitting is a reversal of the removal...Just remember the following: Torque settings, stick to them, a new oil return seal will be needed..

All you have to do is prior to fitting the oil feed pipe is prime the turbo using a small funnel and some clean engine oil spin the compressor wheel whilst you let the oil run through the turbo... don't put too much oil in the funnel as you will have to wait a long time before you can remove it...

Rebuild the car and add new oil and coolant... these procedures are in the haynes manual if you need them...