2016 T6 TSi Engine Failure

[nealfairfield]

Hello collective brain.

Knowledge and advice welcomed please.

After losing power and the engine shutting down a cylinder I pulled over and called the AA. This was their report:

Patrol found the following fault code/s: System : Engine control 1 - VMV / Motronic MED 17.1 UDS Status P 030000 - Combustion failure detected. Error Message : . Static fault. Status P 030400 - Combustion failure cylinder 4 detected. Error Message : . Static fault. Status P 130A00 - Cylinder shutoff. Error Message : . Sporadic fault. Status P 030300 - Combustion failure cylinder 3 detected. Error Message : . Static fault. We have arranged for a recovery of your vehicle. Engine Oil Level Low - Not Topped Up: On min. Coolant Level Ok.

After changing plugs, swapping coils and all other road-side options were carried out, the hope was a failed injector and/or carbon build up. So it was flat-bedded away to get fixed.

Unfortunately, it got worse at the garage with zero compression in cylinder 4 and all this metal in the sump:





Not looking good at all.

I bought it standard in summer 2020 at circa 29k miles. Now 42k.
The van has been without fault until its breakdown. Journeys flex between very short 3-mile round trips in London, to last summer where it took us to the South of France to Tuscany and back perfectly. Mostly city though.
Oil and filter change annually.
In my ownership it has only ever run on premium unleaded. 9 times out of 10 filled with Esso 99 Ron from the same garage which has high turnover. If not there always premium from Shell

Questions:
1. Has anyone ever seen similar with these EA888 engines?
2. What could have caused it?
3. Before getting it rebuilt what other things should be checked to assess whether it's viable (before going the new engine route which is of course ££££)
4. Approximate rebuild costs and any recommended garages in SE London (willing to get it trailered to someone trusted) ?

Many thanks in advance.

N

 

[Loz]

Failed piston..
This looks like parts of the oil control ring from the piston.

 

[nealfairfield]

Failed piston..
This looks like parts of the oil control ring from the piston.
View attachment 187492

Cheers @Loz. Failed piston probably means scored cylinder so looking at rebore. Any ideas why the piston would fail?

 

[Loz]

Did it go lean and melt the side of the piston? looks like the head gasket might have gone as well looking at the oil.
Is it mapped/modified?

 

[nealfairfield]

Did it go lean and melt the side of the piston? looks like the head gasket might have gone as well looking at the oil.
Is it mapped/modified?

It runs a stage 1 from a reputable company that's mentioned many times on this forum. But that was at least 10k of trouble free miles ago.

 

[Big Al]

If an Injector goes faulty it could have been washing the bore with fuel and picked up causing the damage.

 

[nealfairfield]

If an Injector goes faulty it could have been washing the bore with fuel and picked up causing the damage.

Good call. Will definitely get them checked as part of any rebuild. Performance didn’t feel down/ rough prior to failure. Could be a combo of small things. Thx.

 

[Shaun Witts]

My TSI has also done about 42k, and had a Pendle remap in 2020, so I’ll be interested to know any more about the cause of your failure.

 

[nealfairfield]

My TSI has also done about 42k, and had a Pendle remap in 2020, so I’ll be interested to know any more about the cause of your failure.

I'll keep this thread updated with progress and photos as it gets torn down and rebuilt. As soon as you mention a map the instant reply is 'that is what caused it', but it does seem a rare occurrence, especially with many claims these engines' internals are good for up to 500bhp. The first working theory is map-induced pre-ignition causing catastrophic pressure in cylinder 4. Let's see. The internals will tell the true story. Hopefully. Stay tuned.

 

[catfood12]

If an Injector goes faulty it could have been washing the bore with fuel and picked up causing the damage.

I've had the same but different. Blocked injector caused a cylinder to run lean, caused pre-ignition and melted the piston on a supercharged Rover V8 in a Range Rover. I rebuilt the motor, the new one melted, then I found the duff injector and rebuilt it again.....

As Loz said above, that corrugated bit is from the oil control ring, so that's serious piston breakup, not just melted lands on the compression rings. What does it look like when you look up into the crankcase now you have the sump off. I suspect the damage would be visible on number 4 from underneath.

I too understand the EA888s are such a strong engine. Never heard of another blow up that wasn't in a mapped and ragged Golf R...

 

[Paynewright]

Have you still got some old oil? Poss send for analysis - may show up excess fuel.

I’d be checking the crank / shells / oil pump / turbo for damage from swarf dragged through the engine.

Are there any component upgrade opportunities while its in bits?

 

[nealfairfield]

I've had the same but different. Blocked injector caused a cylinder to run lean, caused pre-ignition and melted the piston on a supercharged Rover V8 in a Range Rover. I rebuilt the motor, the new one melted, then I found the duff injector and rebuilt it again.....

As Loz said above, that corrugated bit is from the oil control ring, so that's serious piston breakup, not just melted lands on the compression rings. What does it look like when you look up into the crankcase now you have the sump off. I suspect the damage would be visible on number 4 from underneath.

I too understand the EA888s are such a strong engine. Never heard of another blow up that wasn't in a mapped and ragged Golf R...

Sorry to hear about your RR. A blocked/failed injector is high on the reason why list and will be checked and double checked when apart. You'd hope an ECU should be able to catch the fault before failure though?

Last week was half-term so tear down is only now beginning. Photos will follow when I get them.

 

[nealfairfield]

Have you still got some old oil? Poss send for analysis - may show up excess fuel.

I’d be checking the crank / shells / oil pump / turbo for damage from swarf dragged through the engine.

Are there any component upgrade opportunities while its in bits?

The old-fashioned way of testing the oil said it did have fuel in it. The fuel specialist that drained the tank stuck the dip stick up his nose.

Everything you mention will be checked and double checked. I'm not going through this twice...

Regarding upgrade opportunities it'll only be if the original 100% needs replaced and the upgrade doesn't massively multiply the already unwelcome costs, as I didn't budget for any of this happening. So, so far, only pistons are on the 'maybe' list. JE manufacture a forged option for the EA888.2. Other recommendations welcome.

 

[nealfairfield]

And so it begins. As expected piston #4 is wrecked.

 

[nealfairfield]

Now for some more positive news. Block has been pressure tested and is good. Cylinders very lightly honed and now good. Conrods are good. New bearings installed. New OEM pistons in. Head skimmed, pressure tested and good. Now getting built back up. So far shown.
Tomorrow the ancillaries are tested (injectors, turbo etc) before last push.

 

[nealfairfield]

Hello everyone. Hope good weekends are being had.

An update. I’ve had the van back for a couple of weeks now putting miles on it to run a ‘new’ engine in properly.

If you find yourself in need of a rebuild I can highly recommend www.turn-keyengineering.co.uk . They also operate www.vdubbers.co.uk.

Their usual business is high mile working vans that have lost compression so it’s a fixed, keenly-priced rebuild plus 10 day turnaround. I just paid for pistons on top.

It’s running well. My old map came with a switchable device with settings to cater for different fuel as well as to turn it back to stock, so it’s now back at the original setting with the original factory power.

The van’s a keeper and I don’t want to have to rebuild it again.

Whilst there are no engine lights on I’m making a habit of weekly Carista checks, and this code keeps occurring:
__________

ENGINE
05649 -
Freeze frame :
Priority: 2
Malfunction frequency counter: 1
Unlearning counter: 255
Odometer reading: 67296 km
Engine rpm: 878.00 RPM
Normed load value: 28.2 %
Vehicle speed: 4.0 km/h
Coolant temperature: 63 °C
Intake air temperature: 9 °C
Ambient air pressure: 1010 mbar
Voltage terminal 30: 14.724 V
__________

There doesn’t seem to be much information on this code with only the dodgy looking VWcodes.net returning anything, and it’s not very specific:

“Accumulated in electronic control units so O2 sensor signal bank 1 sensor 1, biased / stuck rich run rough, or might suddenly stall at any given speed direct one reduction catalyst deterioration sensor, circuit low. On the other hand ignition coil ‘f’ primary control, circuit low will delay your vw fault”

“05649 vw fault code may be caused by one or more of the following:

• Manifold Absolute Pressure/Barometric Pressure Circuit High Input
• Fuel Temperature Sensor B Circuit Range/Performance
• Injection Pump Fuel Metering Control 'A' High (Cam/Rotor/Injector)
• Reverse Input Circuit
• O2 Sensor Heater Circuit Malfunction
• Injector Circuit Malfunction - Cylinders
• Injection lump Fuel Metering Control 'B' High (Cam/Rotor/Injector)
• Ignition/Distributor Engine Speed Input Circuit Malfunction”

______

Does any of the above make any logical links to what happened, or what I should watch out for/ be alarmed by?

Thanks for replies as always.

 

[Robert]

Maybe Matti has some more info on your fault code.

 

[mmi]

ENGINE
05649 -

Instead of the above I would look into fault code

5649 - Throttle Control - Airflow at Idle too Low​

The first guess would be to check intake airways for a tiny leak - after air mass meter. Perhpas a split or poor joint which seals itself with more vacuum along more revs.