@Dellmassive`s T6 T32 Sportline 204 LWB DSG PV MY18 - Van Adventure

[Dellmassive]

Looking at the logs when it come back to life.....

Looks like a day to remove the engine.

A day to swap over parts and build the engine on the bench.

A day or two to replace the engine and other parts.

Then test drive and bits.


.

 

[Dellmassive]

A few questions to be answered.....

Was the DMF replaced or did they refit the old one?

Where the existing turbo?. In the back in a box hopefully.

What long block engine has been fitted..... Is it a revised CXEB. Or is it a CXEC?

Need to check that all is well and fitted, long block engine, cat, DPF, oxygen sensor.

Then in addition a new turbo.

We should be expecting clear clean oil.



.

 

[Dellmassive]

UPDATE:

The day has finaly come. . . . .

from 13th Aug 2024 - to 22 November 2024

14 weeks or 3 and a bit months.

Its Back !!!!!!!

all fixed and shiney.

with a brand new CXEB Long Block engine + CAT + DPF + Lamda sensor, - via "All-In" warrenty

plus the warrenty swap DMF. - via 24mnth Parts warrenty

Plus a Brand new Turbo - at my cost.

+++++





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[Dellmassive]

lets have a look at stuff we can see. . .

the engine bay from up topo looks basicaly the same, as the Long Block engine has all of your bolt on ancilleries swapped from the old engine to the new.

so all this is from before.



...

but from underneith it looks a lot shineyer . . .



checking the oil - its so clean you can even see the level. . .



a closer look through the window in the bell housing shows the new DMF too . . .




further back we see the berand new DPF and CAT . . .



...


thats all connected to the rest of the system - ie just the back box left.




its tricky to see the engine block as there is so much stuff wrapped around it. . .

but from this pic, you can see the top of the shiney new Bi-Turbo.



zooming in . . .




..............



i was also left half a bottle of this stuff in the cab, , . .





a quick lookup shows that its a fuel additive. . . they had put in half the bottle, as one bottle does a who tank,

so I've ordered another four bottles from TPS for the next four full tanks of fuel.

i assumed it was for the new engine.

but looking at the paperwork for the new turbo, its part of that work.


either way - new turbo or new engine. been specd and used by VW,

so ill follow there lead and keep adding it in for a while.

5x bottles = 5x 70L tanks of fuel,

to which i do average 400miles/ tank - so that will get me 2000miles bed in period.

them most engines will take 4000miles to 8000miles to properly bed in. - so ill go gentle for the first 4k.

then ill do the 10K oil + Filter change like gospel.

this van i a keeper for me so ill keep to the 10K service intervals from now on.

++++++++++++++++

and sitting in the back of the van is the old turbo. . . its a beast !!

80K on this one and it looks perfect. - no wobble in the spindle or oil leaks.

ill be selling this one as a working unit ready for a direct replacment.










+




.

 

[Howzat]

Just wondering why the new turbo? Belt and braces?

 

[Dellmassive]

so what did the new turbo cost in the end?

well - with 10% parts discound and £0 Labour,

we were at £2582.97 + vat

that gets us to a cool £3099.56 !!!

ouch.

heres the break down,

the main Exhaust manifold + Turbo, with all the required associated parts.

for the CXEB 204ps Bi-Turbo

+++




+++





++++++++++++

heres a closer look at the old one,










.



.

 

[TallPaul_S]

with a brand new CXEB Long Block engine + CAT + DPF + Lamda sensor, - via "All-In" warrenty

Worth the £37 a month then...

 

[Dellmassive]

Just wondering why the new turbo? Belt and braces?

yes kind of,

research on here shows that most people on here show that the 204ps BiTurbo unit needs attention or replacing between 120K miles and 180K miles from new.

so by replaceing mine now ( at 80k miles) . . . im gaurenteed to be happy for the next 120-180k miles in regards to the turbo.

my thinking was that while the engine i out, its a £0 labour for the swap.

versus a possible £1k labour charge a bit later down the line.

the existing turbo is sweet. . . infact the garge called me up to say that - and did i realy want to swap it over?

++++

long story short - i did.

with the idea of keeping this this one for next time round . . or selling onwards.

our other van is a 150ps, so different turbo.

and now we have a new turbo on this van - theres no point in keeping it for the next 6 years. . . so well sell it on to recoupe some of the expence of getting the new one.


..

 

[Dellmassive]

Worth the £37 a month then...

Yep defo.

But the van is six years old now.... And I think it's 6yrs or 100k miles is the max to qualify.

So after this year's cover is up we'll have to see what is available or put my big boy pants on and have no warranty or cover.

But I've always got AA cover to fall back on.

I think you can have the VW assist breakdown cover as a stand alone?

Well have to see.

But for me,.on both vans, the all in package is a no brainer...... Just waiting for the other van to be fixed, it's getting a new DSG gearbox but the factory order part is on back order with no ETA. Which is a pain.

 

[Sackmycook]

Just go for AA, then you can request the VW tech guys

 

[Dellmassive]

Just go for AA, then you can request the VW tech guys

You can only ask for the silver vans when you have the VW assist cover.

With Standard AA you will always get a yellow van..... But that's better than no cover when you're stuck.

 

[Sackmycook]

No mate, I used to work for them. They're one and the same essentially. The silver vans will go to other non-VW jobs.
Just need to request them with a firm tone.....

 

[Dellmassive]

No mate, I used to work for them. They're one and the same essentially. The silver vans will go to other non-VW jobs.
Just need to request them with a firm tone.....

thats interesting to know. . . as I've tried calling out the silver van guys before and got turned away.

after my VW extended warrenty run out, and before i started the ALL-IN package.

i called the VW number and gave reg etc - they said i had no cover.

+++

so called the AA number for a call out ( been with the AA for over 20yrs now ) - and got the yellow van out.

but must admit i didnt try asking for the silver van guys from the standard AA call center.

thats defo worth a try in future.

 

[jimc91]

Great result all round….

 

[Dellmassive]

lets have a look at stuff we can see. . .

the engine bay from up topo looks basicaly the same, as the Long Block engine has all of your bolt on ancilleries swapped from the old engine to the new.

so all this is from before.

View attachment 266191

...

but from underneith it looks a lot shineyer . . .

View attachment 266192

checking the oil - its so clean you can even see the level. . .

View attachment 266193

a closer look through the window in the bell housing shows the new DMF too . . .


View attachment 266194

further back we see the berand new DPF and CAT . . .

View attachment 266195View attachment 266196

...


thats all connected to the rest of the system - ie just the back box left.

View attachment 266197


its tricky to see the engine block as there is so much stuff wrapped around it. . .

but from this pic, you can see the top of the shiney new Bi-Turbo.

View attachment 266198

zooming in . . .

View attachment 266199


..............



i was also left half a bottle of this stuff in the cab, , . .


View attachment 266200


a quick lookup shows that its a fuel additive. . . they had put in half the bottle, as one bottle does a who tank,

so I've ordered another four bottles from TPS for the next four full tanks of fuel.

i assumed it was for the new engine.

but looking at the paperwork for the new turbo, its part of that work.


either way - new turbo or new engine. been specd and used by VW,

so ill follow there lead and keep adding it in for a while.

5x bottles = 5x 70L tanks of fuel,

to which i do average 400miles/ tank - so that will get me 2000miles bed in period.

them most engines will take 4000miles to 8000miles to properly bed in. - so ill go gentle for the first 4k.

then ill do the 10K oil + Filter change like gospel.

this van i a keeper for me so ill keep to the 10K service intervals from now on.

++++++++++++++++

and sitting in the back of the van is the old turbo. . . its a beast !!

80K on this one and it looks perfect. - no wobble in the spindle or oil leaks.

ill be selling this one as a working unit ready for a direct replacment.





View attachment 266201




+




.

We finally got some paperwork from the dealers for the CXEB engine swap. . .

its 10 pages long !!!

the BiTurbo is on separate paperwork, - as i paid for that.

the DMF is on separate paperwork as that was under 24mnth parts warranty.

looking like:
£7871 Base Engine
£1845 DPF
£1440 CAT
£295 Oxygen sensor
plus all the other bits,
plus labour
plus VAT


lets take a look. . . . . .

+++



..


.


.



.




















.

 

[Sackmycook]

So you paid 20% yourself?

 

[Pauly]

£98 an hour + vat, and thats warranty rate, wonder what their normal hourly rate is for retail customers !

 

[Dellmassive]

So you paid 20% yourself?

No, I paid £0 for the warranty work.

I had to authorize the original diagnostic work circa £500 for the oil loss and compression test. (In case that wasn't the problem)... But I never actually paid anything... And that charge was covered under warranty.

The only thing I paid for was the new turbo.(That it didn't need, but I wanted anyway)

The turbo and DMF are on separate paperwork.

FYI - the service manager did say the paperwork was for reference only.... It's my proof that the parts/ work has been done.... But the actual prices and rates are between the dealership and the WV All-in insurance. So none of my concern.

But it makes interesting reading.

The amount of additional new nuts and bolts etc that are required to be fitted by VW are astonishing..... And I've watched serval cxeb engine rebuild videos where the original bits were refitted..... For example brand new engine mount bolts.(Nothing wrong with the previous ones I'd assume) but the service manager said VW were very specific.... And if even one bolt was not replaced as per the service manual then there claim would be refused....at any point in the future. As in a tech could review that case 6mnths down the line and decide a bracket wasn't replaced at the time and then reflect the whole job and take the warranty money back from the dealership... Which is why the garage was so finiky.


****

Another thing to fall foul of is Mapping.

The garage was convinced that my van was mapped.... Which it isn't and never has been...

But apparently they couldn't get the engine ECU data from the van?

I even had to remove the ghost immobilizer myself in case that was a factor (it wasn't).

They even said they had to wait for a like for like van to compare!!! - jeez. But it all worked out well in the end.

@Deaky has just come into this problem.... He has full All-in warranty, and his DSG box, DMF and drive shaft have failed... (Something I need to look into as it looks like it's more common than we thought on the DSG box) - anyway this would all be covered under all in.

BUT VW have rejected his claim as the DSG gearbox had a TVS map on it....he could be looking at a £5k+ bill now.

So think twice about mapping and modifying before your warranty runs out.

.

 

[Dellmassive]

£98 an hour + vat, and thats warranty rate, wonder what their normal hourly rate is for retail customers !

Double that id imagine..

 

[Deaky]

BUT VW have rejected his claim as the DSG gearbox had a TVS map on it....he could be looking at a £5k+ bill now.

So think twice about mapping and modifying before your warranty runs out.

.

Ain't that the truth. Final quote is in at 8k plus VAT. Fly wheel, Gearbox and offside driveshaft.

Just getting a quote of a VW approved garage at the moment rather than main dealer. They are coming in at 7k so a grand cheaper, but I'm already into VW for removing the gear box and their diagnostic charge so by the time I've trailered the van to the other garage I don't think I'd be any better off.