PSA/Ford 1.6 HDi and 1.6 TDCi (DV6): common problems by mileage
The 1.6 HDi/TDCi (DV6) was developed by PSA and Ford and is found in Peugeots, Citroëns, Fords, Volvos, Mazdas and Minis from 2004. Early engines are 16-valve; from 2010 an 8-valve version (DV6C, e-HDi) took over. Its signature problem is carbon: from leaking injector washers and in the oil, ending in a turbo starved of oil.
Updated · written by ipacen from documented workshop experience
- Engine codes
- DV6TED4 (9HY, 9HZ), DV6ATED4 (9HX), DV6C (9HR, 9HP); Ford G8DA, HHDA and others
- Displacement
- 1,560 cc
- Power
- 55–88 kW (75–120 hp)
- Built
- 2004–2018
- Timing drive
- Belt (16-valve versions add a short chain between the camshafts)
- Fuel system
- Common rail
Problems at a glance
| Problem | Typical mileage |
|---|---|
| Leaking injector washers ("black death") medium severity | 60,000–180,000 km 35,000–110,000 miles |
| Turbo failure from a blocked oil feed high severity | 100,000–220,000 km 60,000–135,000 miles |
| Particulate filter additive running out medium severity | 80,000–200,000 km 50,000–125,000 miles |
Leaking injector washers ("black death")
Symptoms
- Puffing or ticking noise near an injector
- Black, tar-like carbon around the injector
- Smell of exhaust under the bonnet or in the cabin
- Hard starting and rough idle on that cylinder
Fault codes
Usually no generic fault code: go by the symptoms and the tests below.
Why it happens
The copper washer under the injector stops sealing (wrong torque, reused clamp bolt, age), so combustion gas escapes past it. The carbon it leaves cements the injector into the head and finds its way into the oil.
How to confirm it
- With the engine running, look and listen around each injector; soapy water shows bubbles at a leaking one.
- Look for a crust of black carbon in the injector well.
- Check the oil for carbon (black sludge on the dipstick or filler cap).
The fix
Remove the injector (often seized: penetrating oil and a puller), clean the bore and seat, fit a new washer and clamp bolt and tighten to the specified torque.
Prevention
New washer and bolt every time an injector comes out, torqued correctly.
Turbo failure from a blocked oil feed
Symptoms
- Whistle or siren noise from the turbo
- Blue or black smoke and loss of power
- Underboost fault code
- Oil in the intercooler and hoses
Fault codes
Why it happens
Carbon and sludge in the oil block the fine filter in the turbo oil feed banjo bolt and the sump pickup strainer. The turbo then runs short of oil and its bearings fail, often again soon after a new one is fitted.
How to confirm it
- Check turbo shaft play and oil in the inlet and outlet.
- Remove the oil feed banjo bolt and inspect its filter screen.
- Drop the sump and check the pickup strainer for carbon.
The fix
New turbo with a new oil feed pipe from the manufacturer's updated kit, clean or replace the sump pickup strainer, flush, fresh oil and filter. Fix any injector washer leak, or the carbon comes back.
Particulate filter additive running out
Symptoms
- DPF or additive warning, then limp mode
- Frequent regenerations and a rising soot load
- Additive level or quantity fault stored
- Fluid leaking around the additive tank near the fuel tank
Fault codes
Why it happens
On versions whose filter uses an additive (Eolys or PowerFlex), the ECU doses it into the fuel so the soot burns at a lower temperature. When the additive runs out, or its pump or line fails, the filter stops regenerating properly.
How to confirm it
- Read the additive quantity counter and filter data with a tool that supports PSA or Ford systems.
- Check the additive tank or bag, pump and line for leaks.
- Measure soot load and differential pressure before deciding on cleaning.
The fix
Refill or replace the additive tank or bag with the correct fluid for that system, reset the counter with a diagnostic tool, then run a forced regeneration. A filter full of ash needs replacing.
Known-good values
Add readings from a healthy 1.6 HDi/TDCi DV6Readings from 1.6 HDi/TDCi DV6 engines that run correctly, reported by mechanics on ipacen. Each member counts once; the median shows from 3 members up, with the middle half of the readings as the range. No readings yet: be the first.
See the values you can report and the typical guide
| Value | Typical guide | Measured by members |
|---|---|---|
| Engine | ||
| Idle speed, warm (rpm) | Usually about 650–900 rpm | — |
| Coolant temperature, fully warm (°C) | About 85–105 °C | — |
| Oil pressure, hot idle (bar) | Typically above about 1.0 bar | — |
| Oil pressure, hot, 2,000 rpm (bar) | Typically above about 2.5 bar | — |
| Compression, typical cylinder (bar) | Petrol about 11–15 bar, diesel about 25–35 bar | — |
| Air and fuel | ||
| Air mass, warm idle (g/s) | Petrol: roughly 1 g/s per litre of engine size | — |
| Air mass, warm idle (as mg per stroke) (mg/stroke) | Compare with specified in live data; changes with EGR | — |
| Boost at full load (absolute) (mbar) | Turbo engines: compare with specified boost | — |
| Fuel system | ||
| Fuel pressure, low-pressure side, idle (bar) | Check the specification for the system | — |
| Rail pressure, warm idle (bar) | Diesel common rail: typically about 250–400 bar | — |
| Rail pressure while cranking (bar) | Typically past about 200–300 bar within 1–2 s | — |
| Largest injector correction, warm idle (mg/stroke) | Typically within about ±2–3 mg per stroke | — |
| Emissions | ||
| Particulate filter differential pressure, warm idle (mbar) | Low on a clean filter; compare with the reading at 2,500 rpm | — |
| Electrical | ||
| Charging voltage, 2,000 rpm (V) | About 13.8–14.7 V | — |
| Lowest battery voltage while cranking (V) | Above about 9.6 V | — |
| Crankshaft sensor resistance (inductive type) (Ω) | About 200–2,000 Ω | — |
The guide is ipacen's typical range, not manufacturer data. Member values are what colleagues measured on healthy cars; always compare with the specification for the engine.
Which cars have the 1.6 HDi/TDCi DV6
- Peugeot: 206, 207, 208, 307, 308, 3008, 407, 508, Partner
- Citroën: C3, C4, C4 Picasso, C5, Berlingo, Xsara Picasso, DS3, DS4, DS5
- Ford: Fiesta, Fusion, Focus II and III, C-Max
- Volvo: S40, V50, C30, V40 (2012–), S60/V60 1.6 D
- Mazda: Mazda3 (BK, BL) 1.6 CD
- Mini: One D and Cooper D (R55 to R60, about 2007–2014)
Cases with this engine
Share yours1.6 HDi/TDCi DV6: questions and answers
What are the most common problems with the 1.6 HDi/TDCi DV6?
The most reported are leaking injector washers ("black death"); turbo failure from a blocked oil feed; particulate filter additive running out. Each one is described below with its symptoms, fault codes, how to confirm it and the usual fix.
At what mileage does the 1.6 HDi/TDCi DV6 have leaking injector washers ("black death")?
Typically between 60,000–180,000 km (35,000–110,000 miles), depending on use and maintenance. The copper washer under the injector stops sealing (wrong torque, reused clamp bolt, age), so combustion gas escapes past it. The carbon it leaves cements the injector into the head and finds its way into the oil.
At what mileage does the 1.6 HDi/TDCi DV6 have turbo failure from a blocked oil feed?
Typically between 100,000–220,000 km (60,000–135,000 miles), depending on use and maintenance. Carbon and sludge in the oil block the fine filter in the turbo oil feed banjo bolt and the sump pickup strainer. The turbo then runs short of oil and its bearings fail, often again soon after a new one is fitted.
At what mileage does the 1.6 HDi/TDCi DV6 have particulate filter additive running out?
Typically between 80,000–200,000 km (50,000–125,000 miles), depending on use and maintenance. On versions whose filter uses an additive (Eolys or PowerFlex), the ECU doses it into the fuel so the soot burns at a lower temperature. When the additive runs out, or its pump or line fails, the filter stops regenerating properly.
Which cars have the 1.6 HDi/TDCi DV6 engine?
Peugeot: 206, 207, 208, 307, 308, 3008, 407, 508, Partner. Citroën: C3, C4, C4 Picasso, C5, Berlingo, Xsara Picasso, DS3, DS4, DS5. Ford: Fiesta, Fusion, Focus II and III, C-Max. Volvo: S40, V50, C30, V40 (2012–), S60/V60 1.6 D. Mazda: Mazda3 (BK, BL) 1.6 CD. Mini: One D and Cooper D (R55 to R60, about 2007–2014).
Mileage windows are typical workshop experience, not manufacturer data. Engines vary by version, use and maintenance; always follow the service information for the vehicle.