2016 180 Bi turbo CFCA engine failure is the EGR valve corrosion the cause of the scored and worn out bores

[Digitaldug]

Thanks CarreraRSR. Are you saying that the gasket should be on the high pressure side? Sorry, it’s not obvious to me which side (top or bottom of blanking plate) that is for the left and right pipe.

 

[DXX]

No need to remove the oil filter.
On the pipe from the exhaust manifold to the EGR: the gasket goes against the pipe face.
On the pipe between the EGR and the inlet: the gasket goes on the pipe face on the lower flange.
It helps to slightly loosen the top flange on the front pipe to get enough movement to get the blanks in.

 

[AndieH]

The emulator is not connected to an EGR, it is an EGR emulator so the wiring from the engine harness plugs into the emulator and the emulator pretends to be an EGR. This keeps the ECU happy. The actual on-engine EGR is no longer connected to any wiring harness in any way. In case the actual EGR is still open or leaking exhaust gas into the inlet manifold, you fit the blanking plates. This stops any unintentional exhaust gas recirculation into the inlet. You can buy the Tafmet on it's own and make up or buy different blanking plates from somewhere else. Check out the Tafmet website.

The CFCA engine was fitted in T5 and T6 before is was replaced with a Euro 6 biturbo. I asked Tafmet if this works on a T6 and they said it does as it's the same engine and ECU. I can confirm it works fine on my 2016 T6 180 CFCA.

I have a T6 BiTDI so does this mean I won’t have this problem as all I see said is don’t touch a bi turbo but no real idea why? Appreciate any help.

 

[WinFreak]

I have a T6 BiTDI so does this mean I won’t have this problem as all I see said is don’t touch a bi turbo but no real idea why? Appreciate any help.

The T6 bitdi hasn't got the same issues as the T5 but a whole new range of them!

 

[AndieH]

The T6 bitdi hasn't got the same issues as the T5 but a whole new range of them!

Such as?

 

[Optimol]

I have a 2017, T6.1 with the 204ps BiTDi engine and this has had an EGR cooler failure! This was at around 30k miles. Emulsion in the oil filler was evident so took it to VW dealer who changed the EGR valve and told me it would be OK now. What I didn't realise at the time (but certainly do now) was that irrepairable damage had already been done to the engine as a result of the failure. Not long after this the oil consumption was noticeably getting worse and this affected the DPF and SCR such that the engine warning light illuminated. System flushes by the dealer only resulted in a short term "fix" because after about 60 miles the engine warning light (orange) illuminated again.
Dealer wanted ca. £15k to replace the engine and VW customer service UK refused to discuss the problem.

I am now looking at stripping and re-building the engine but am concerned that it may require more than a re-bore and new pistons and rings. If other major comp
onents are also damaged, e.g. turbos then the total rebuild cost at retail prices could end up approaching the VW quote.

Does anyone have any experience of doing a rebuild after this type of damage and how extensive was the damage?

Does anyone know a reputable organisation that does rebuilds or exchange engines?

 

[paradigm]

My genuine condolences.
Only thing I can recommend is to talk to either Retro Resus in Somerset or Darkside Developments if you're up north. Best of luck!

 

[eugene]

I have a 2017, T6.1 with the 204ps BiTDi engine and this has had an EGR cooler failure! This was at around 30k miles. Emulsion in the oil filler was evident so took it to VW dealer who changed the EGR valve and told me it would be OK now. What I didn't realise at the time (but certainly do now) was that irrepairable damage had already been done to the engine as a result of the failure. Not long after this the oil consumption was noticeably getting worse and this affected the DPF and SCR such that the engine warning light illuminated. System flushes by the dealer only resulted in a short term "fix" because after about 60 miles the engine warning light (orange) illuminated again.
Dealer wanted ca. £15k to replace the engine and VW customer service UK refused to discuss the problem.

I am now looking at stripping and re-building the engine but am concerned that it may require more than a re-bore and new pistons and rings. If other major comp
onents are also damaged, e.g. turbos then the total rebuild cost at retail prices could end up approaching the VW quote.

Does anyone have any experience of doing a rebuild after this type of damage and how extensive was the damage?

Does anyone know a reputable organisation that does rebuilds or exchange engines?

Very sorry to hear your story. Unbelievable that the dealer refused warranty. I hope you will be able to get it back on the road.

 

[DXX]

I have a 2017, T6.1 with the 204ps BiTDi engine and this has had an EGR cooler failure! This was at around 30k miles. Emulsion in the oil filler was evident so took it to VW dealer who changed the EGR valve and told me it would be OK now. What I didn't realise at the time (but certainly do now) was that irrepairable damage had already been done to the engine as a result of the failure. Not long after this the oil consumption was noticeably getting worse and this affected the DPF and SCR such that the engine warning light illuminated. System flushes by the dealer only resulted in a short term "fix" because after about 60 miles the engine warning light (orange) illuminated again.
Dealer wanted ca. £15k to replace the engine and VW customer service UK refused to discuss the problem.

I am now looking at stripping and re-building the engine but am concerned that it may require more than a re-bore and new pistons and rings. If other major comp
onents are also damaged, e.g. turbos then the total rebuild cost at retail prices could end up approaching the VW quote.

Does anyone have any experience of doing a rebuild after this type of damage and how extensive was the damage?

Does anyone know a reputable organisation that does rebuilds or exchange engines?

I’d say that there will be more to repair than the cylinders, the longer the water is in the engine the worse the corrosion, the longer it was driven in that condition the worse the wear.
Unless you are doing the work yourself you will probably be better off with a new / re-con short engine and get the turbocharger assembly stripped asap and survey the damage.

It’s worth noting that the CXEB EGR cooler failure mechanism is not the same as the common CFCA problem and there is no link.
Probably worth moving your CXEB content off this CFCA content to avoid confusion.