2016 180PS Bi-TDi CFCA engine failure
- Thread starter venables
- Start date
-
- Tags
- 180ps bi-tdi cfca engine egr
And indeed, there are fairly recent software updates for CFCA ECU variants
Just to name a few...
Welcome to VAG-Flashinfo!
VAG Flashfiles Informations - Version check of VAG ECUs - Update check for Audi, Seat, Skoda and Volkswagen
vag-flashinfo.de
Welcome to VAG-Flashinfo!
VAG Flashfiles Informations - Version check of VAG ECUs - Update check for Audi, Seat, Skoda and Volkswagen
vag-flashinfo.de
Welcome to VAG-Flashinfo!
VAG Flashfiles Informations - Version check of VAG ECUs - Update check for Audi, Seat, Skoda and Volkswagen
vag-flashinfo.de
Welcome to VAG-Flashinfo!
VAG Flashfiles Informations - Version check of VAG ECUs - Update check for Audi, Seat, Skoda and Volkswagen
vag-flashinfo.de
The same seems to be true also for the other T5.1 engine variants CAAA, CAAB, CAAC, CAAD, CCHA.
So after applying Google Translate to www.wnwalt…… it seems that the software change is to increase the period the EGR is in operation for legal reasons. Given that most vans on the road over a couple of years old are probably suffering from coked open EGR valves is it going to make a difference.
And indeed, there are fairly recent software updates for CFCA ECU variants
Just to name a few...
Welcome to VAG-Flashinfo!
VAG Flashfiles Informations - Version check of VAG ECUs - Update check for Audi, Seat, Skoda and VolkswagenWelcome to VAG-Flashinfo!
VAG Flashfiles Informations - Version check of VAG ECUs - Update check for Audi, Seat, Skoda and VolkswagenWelcome to VAG-Flashinfo!
VAG Flashfiles Informations - Version check of VAG ECUs - Update check for Audi, Seat, Skoda and VolkswagenWelcome to VAG-Flashinfo!
VAG Flashfiles Informations - Version check of VAG ECUs - Update check for Audi, Seat, Skoda and Volkswagen
The same seems to be true also for the other T5.1 engine variants CAAA, CAAB, CAAC, CAAD, CCHA.
I certainly wouldn’t be making this change to my van, even more soot re-entering the engine causing contamination and wear.
I was a bit worried but now after reading the translation of this, I am really crapping it! (VW did the 23DV update on my van this week)
I have managed to do nearly 300 miles since the service on Tuesday and also do some poking around using OBD11. I can see that the soot measured and calculated at the DPF is very slow to increase and it seems the regens happen properly. (seems the van only needed to do 1 regen today as I covered 130miles on motorways and dual carriageways).
My plan so far is to fit the Tafmet which hopefully arrives tomorrow, keep driving until 1000miles have passed since the oil change this week and then send off the oil for analysis. If the oil report is Ok then I'll carry on until the next service but if not, then I'll change the oil again. Based on the encouraging DPF readings, I am hopeful that I have caught this in time.
Last edited:
I just did mine today and it was a massive pain in the a. Right pipe took 10mins, the left took 3 hours. Someone must have changed the egr cooler under warranty as the left top and bottom screws nearest the radiator were cross-threaded. Managed to sort the top but the bottom was wrecked as the thread in the aluminium egr cooler were stripped. Luckily, the thread goes deeper than the screw so made up a longer one with a nut and washer for tightening. Test drive for 45miles was fine; the van even feels more responsive now. Can't say as its exactly discreet though as you can't hide all the cabling to the Tafmet.
I have installed the engine and battery covers. If the mot tester knows what he’s looking for he may spot two link pipes missing.
Have you removed the flexi pipes to the egr then?
Yes. The Darkside Dev blanking plates were too thick to slide in and retain the pipes. I’ve considered getting the pipes welded/blocked off and refitting them so it looks OEM. Just not gotten round to it. Mot due September. So times ticking.
You can make it discreet with careful routing and use of alternative matching harness tape.
In addition fitting a dummy plug in the now empty EGR valve socket and taping into the harness completes the job.
Plenty of stainless steel shim and gasket sheet available on ebay, very easy to make your own.
I have a 2016 180 biturbo DSG has covered 66k I have annual service and oil change, the van does not use any oil to speak of and have only topped up once when near it's service.
I have checked the label on the EGR cooler and it is the revised one but from the horror stories here it would seem so far I have been lucky, I am now thinking to get the egr blanked off will this have any issues regarding MOT just had an MOT and the readings were low. I will need to get someone to delete the EGR from the ECU correct?
My van is Euro 5 and was a month out from being a Euro 6 which never bothered me but Mr Khan's expansion of the ULEZ is going to be a factor soon as I am sure other cities will follow. I did hear somewhere that it could be possible to get the van recalibrated through DVLA (is that Bullshit) The Mot tester said the emissions from my van were the same as the allowance on some Euro 6 .
The van is due it's annual service now, should I get the garage to give me some of the old oil to get an analysis, how much do you need?
Thanks
I have checked the label on the EGR cooler and it is the revised one but from the horror stories here it would seem so far I have been lucky, I am now thinking to get the egr blanked off will this have any issues regarding MOT just had an MOT and the readings were low. I will need to get someone to delete the EGR from the ECU correct?
My van is Euro 5 and was a month out from being a Euro 6 which never bothered me but Mr Khan's expansion of the ULEZ is going to be a factor soon as I am sure other cities will follow. I did hear somewhere that it could be possible to get the van recalibrated through DVLA (is that Bullshit) The Mot tester said the emissions from my van were the same as the allowance on some Euro 6 .
The van is due it's annual service now, should I get the garage to give me some of the old oil to get an analysis, how much do you need?
Thanks
My advice is once you see oil consumption the wear has already started so fit a Tafmet kit now. No need to map anything.
As for re-calibrating a Euro 5 to a Euro 6, not unless you know a bent individual at DVLA I guess. Your Euro 5 does output the same CO2 as a Euro 6, however Euro 6 is about NOX emission reduction not CO2, hence the Adblue injection into the exhaust.
Oil analysis could be done by yourself if you can pull out the dipstick and use a syringe / plastic hose in the dipstick tube, from memory it’s 75mL. The Miller kit does not include the tube and syringe which are cheaply available on Ebay.
Be careful not to contaminate the sample and to ensure that the data entered on the form is accurate.
I’ve put my Euro 5 through 2 MOTs and the emissions have not been checked as the tester has said it‘s not possible.
I don't believe the CFCA was ever a Euro 6 and ever had AdBlue did it? So regardless of dates, your vehicle wouldn't/couldn't be EU6 at a later date.
Order a Millers kit direct from them. Put in 75-100ml of old oil and post it off. You'll get a report back within 5 days usually with the state of health of the engine. Key watch out is high aluminium content which will trigger concerns that the EGR cooler is breaking down and ally oxide is entering the engine. Regardless, I would recommend having the EGR blanked off at both ends and use piggy back Tafmet solution as DXX proposes. Other route is mapping out, but needs a specialist which is the route I took. Tafmet is DIY and overall cheaper to do.
Your recent MOT and emissions readings have nothing to do with the EGR degrading. That's unless the engine wear and oil burning was at such a level litres of oil are being burned through the exhaust pipe.
Fingers crossed all remains good for us all.
yes Cheers
I followed the general advice above. The oil change had been done and the van driven 315miles before I fitted the EGR blanking and the Tafmet. I've now done 897 miles since the oil change and EGR blanking so I took a sample today and sent it off to Millers for analysis. They ask you to fill the bottle which is 80ml. You will get the results back via email. Hopefully, I will get good news......
FYI: It's hard to say if there is any difference or maybe placebo effect but the van seems to run smoother and slightly better mpgs since the EGR blanking and Tafmet install. I checked for fault codes and there isn't any. My wife took the van to Cornwall at the weekend (600 mile round trip) and got back last night. The measured soot at the DPF is very low at 1.59 grams so I am hopeful I caught it before the damage started.
I also have the dummy plug that DXX advised to fit. It will give the impression to any prying eyes that the EGR is plugged in and protect the connecting pins from being exposed to dirt and rust. Found mine on eBay here for £6.99: 6 Pin EGR Valve Connector Plug Wire Harness For Audi VW Seat Skoda 1J0973713G 5051154194546 | eBay
Last edited:
To back-up the advise given by the contributors above, I can confirm prevention is better than cure. I blanked off my EGR and fitted the Tafmet as I was worried that the EGR would soon cause major issues. (Seems EGR will certainly fail, just a matter of when...) I did 897 miles on fresh oil and then sent a sample off for analysis. The results are good so I will now take another sample at 4000 (currently on 2000 miles) and see how that looks. It seems I have caught this early or before the failure mode.
At 3k on the current oil I will do the same. Its had three oil and filter changes in less thn 3k miles, and I have to top up quite a bit when driving loaded. I have a oil analysis kit here so might do it after the summer of big trips.
I am deciding on either cut-and-run next spring and add a further £20-25k and buy a ULEZ 2016+ or go new VW create engine with Retro Resus for £10k in my great condition 2014 van. My other concern is I want another Caravelle dsg 4motion so its going to be another BiTDI (204) that might have the same issues...
I am deciding on either cut-and-run next spring and add a further £20-25k and buy a ULEZ 2016+ or go new VW create engine with Retro Resus for £10k in my great condition 2014 van. My other concern is I want another Caravelle dsg 4motion so its going to be another BiTDI (204) that might have the same issues...
Have you blanked the EGR now? If this is the first oil analysis then 3k should be plenty to give you a baseline of wear and possible EGR failure. Your oil consumption may be down to other reasons such as turbo seals.
Agreed. Yes the EGR (an A 
) is now blanked and mapped out by Retro Resus.
First oil analysis was when I first bought it and Millers said the oil was very old so hard to tell.
"As you are probably aware, with the VW 2.0 L BiTDI 180 hp CFCA engine as used in your Caravelle, the issue we see regularly is the breakdown of the cooler on the EGR, this gives Aluminium salt particles which are ingested by the engine causing bore damage leading to poor compression and excessive oil consumption; we see this as Aluminium in the oil. Your oil sample is actually not too bad in this respect but does have a fail level of Aluminium present.
Due to the high levels of soot, fuel, Iron and a general aged appearance, I am wondering if the oil is somewhat older than the 5876 miles you state. Rather than panic at the poor condition of the oil and what that means for the health of the engine, I suggest that you monitor the oil going forward now you are able to know for a fact the mileage on the oil. Starting with fresh oil, use the van for 3000 miles or so and have another test. If there are issues, we will see them and you will have the information to take appropriate action."
I then changed the oil and fileter the next day after buying, drove to Retro Resus and they did it again, and then after about a month and replacing the DPF, we watched the oil then blanked off the EGR and flushed and changed the oil again. Waiting for 3k'ish to roll around...
It runs, it goes like hell, it starts on the button and it returns 37'ish on a run not loaded to the roof, 30'ish loaded up with camping kit/kids and 4-6 bikes. If I can get to Spring 2024 its decision time. Its straight as anything underneath and in amazing condition for the 136k miles, its mint inside now, a few dents outside which I am cool about, I have replaced everything worn baring the rear brakes so far. I am feeling better the devil I know and just live with ULEZ expansion (we are two miles away but mostly use this vehicle heading out of London and not in). I would love to a compression test but cant get anyone local to do it, or find the right tools myself
...
) is now blanked and mapped out by Retro Resus.First oil analysis was when I first bought it and Millers said the oil was very old so hard to tell.
"As you are probably aware, with the VW 2.0 L BiTDI 180 hp CFCA engine as used in your Caravelle, the issue we see regularly is the breakdown of the cooler on the EGR, this gives Aluminium salt particles which are ingested by the engine causing bore damage leading to poor compression and excessive oil consumption; we see this as Aluminium in the oil. Your oil sample is actually not too bad in this respect but does have a fail level of Aluminium present.
Due to the high levels of soot, fuel, Iron and a general aged appearance, I am wondering if the oil is somewhat older than the 5876 miles you state. Rather than panic at the poor condition of the oil and what that means for the health of the engine, I suggest that you monitor the oil going forward now you are able to know for a fact the mileage on the oil. Starting with fresh oil, use the van for 3000 miles or so and have another test. If there are issues, we will see them and you will have the information to take appropriate action."
I then changed the oil and fileter the next day after buying, drove to Retro Resus and they did it again, and then after about a month and replacing the DPF, we watched the oil then blanked off the EGR and flushed and changed the oil again. Waiting for 3k'ish to roll around...
It runs, it goes like hell, it starts on the button and it returns 37'ish on a run not loaded to the roof, 30'ish loaded up with camping kit/kids and 4-6 bikes. If I can get to Spring 2024 its decision time. Its straight as anything underneath and in amazing condition for the 136k miles, its mint inside now, a few dents outside which I am cool about, I have replaced everything worn baring the rear brakes so far. I am feeling better the devil I know and just live with ULEZ expansion (we are two miles away but mostly use this vehicle heading out of London and not in). I would love to a compression test but cant get anyone local to do it, or find the right tools myself
...Similar threads
