Mazda 3 1.6 PSA Intake and intercooler full of oil

[Ronann]

Hi,
I have a 2012 Mazda 3 with the 1.6 PSA diesel engine. The intake and intercooler is caked in dripping oil, I know a bit of oil is normal but this seems excessive. Car produces some blue smoke on startup then goes away, also noticed when I was behind my dad while he was driving it a puff of black smoke came out the back when he floors it.

Is it the turbo seals going bad? There isn't any play in the shaft and has plenty of power but it kinda makes a whining noise when I rev it which is making me believe the turbo is going bad. It has 140k miles on the clock.
I checked the rubber diaphragm for the PCV system and its in good condition. Getting fedup with the car now as I've had injector issues and the clutch just failed as well. The 1.6 really is a horrible engine, won't be buying another haha.

 

[Burnerman]

Sadly I think your diagnosis is likely to be correct.....the DV6 does have a weakness regarding the turbo oil supply unless the servicing regime is strictly attended to.
Modifications include removing the oil mesh filter in the turbo oil supply and cleaning the oil strainer gauze in the sump.
John

 

[Ronann]

Yeah not a very good engine I'm afraid. There's just one thing after another to replace on the car. I've had 2 injectors fail within 5000 miles of eachother, I imagine the other two are gonna fail soon as well.

 

[sxturbo]

There a great engine but need regular servicing.

The turbo also needs proper cool down period by idling for 30 seconds to a minute after driving.

The service interval also needs to be cut in half because the service schedule set out by the dealers is far to long, the sump is to small for the miles they say. They also gave it long service intervals to compete with the competition which was a bad move.

Your diagnosis is correct, the intercooler and the intake manifold will need to be removed and cleaned, you will also need to clean the intake ports of the head as these are likely coked up with carbon also causing a restriction.

If installing a new turbo ensure the upgraded oil feed and drain pipes are also fitted. You will also need to have the engine oil flushed.

If the above is not done then the turbo won't be warranted. But this is for the garage to worry about

 

[Burnerman]

Good advice......
I’ve dropped the sump on two of these ( Both Berlingo vans) and the strainers were clear in both cases.
I’ve heard that Citroen won’t do this repair and insist on replacing the engine.....don’t know how true that is though.
John

 

[Keithmac]

I'm sure this engine is also fitted to Ford Focus, my mate had terminal turbo failure due to the blocked supply filter (what a stupid design).

Scrapped the car iirc.

 

[Ronann]

Yeah, that stupid gauze filter on the oil supply line isn't a good design. I'm surprised the engineers didn't think that it would eventually get blocked and then cause the turbo to take a dump. I'd rather have no filter on it and not have to worry about it. Debris going through the turbo shouldn't be an issue if you keep on top of oil changes anyway.

 

[sxturbo]

Good advice......
I’ve dropped the sump on two of these ( Both Berlingo vans) and the strainers were clear in both cases.
I’ve heard that Citroen won’t do this repair and insist on replacing the engine.....don’t know how true that is though.
John

The strainers tend to be clear on these, but the oil feed pipe tends to clog itself with carbon from the oil, they did have f

I'm sure this engine is also fitted to Ford Focus, my mate had terminal turbo failure due to the blocked supply filter (what a stupid design).

Scrapped the car iirc.

Yeah focus, fiesta, all Citroen Peugeot, BMW minis, various Volvo's, fiat vans, they are fired in an awful lot of vehicles

 

[Keithmac]

The strainers tend to be clear on these, but the oil feed pipe tends to clog itself with carbon from the oil, they did have f


Yeah focus, fiesta, all Citroen Peugeot, BMW minis, various Volvo's, fiat vans, they are fired in an awful lot of vehicles

Our Mk2 Kuga has the 2l Diesel PSA 163 engine, seems they got it right with that one, saying that it gets 6,000 mile oil and filter changes..

 

[sxturbo]

Our Mk2 Kuga has the 2l Diesel PSA 163 engine, seems they got it right with that one, saying that it gets 6,000 mile oil and filter changes..

Yeah the 2.0 didn't suffer the issues,

I believe the issues are down to the size of the sump and the extended drain servicing,

It's very good that you do a service every 6k people tend to forget that the cost of oil and filters are less than the cost of a new engine. It's much better to "over service" than under service.

Most people don't even bother thinking about servicing until the light flashes up, and even then they leave it usually until the mot is due and get it done at same time, etc etc I could go on about it.

 

[Keithmac]

I service motorcycles with 1.2l of engine oil sump capacity and 6,000 mile intervals (exact same engine used to have 3000 mile oil changes!).

All they did was fit brake pads with thicker friction material and specified fully synthetic oil which was tripple the cost of the earlier oil.spec.

Same with "Long Life" oil in BMW's, same oil for 20,000 miles, no thanks..