MIA
Veteran Member
I apologize about the long post but here goes...
Before we get started: My car is a 2001 Golf GLS Auto with approximately. 38500 miles. No mods ever done to the engine, religiously changed with Delvac 1/CAT oil at 10k intervals. TB kit purchased from Diesel Geek with all the correct part numbers.
(Just to let you know I am not a mechanic and all I can do is present what I remember being told the best I can)
This Saturday I had a respected TDI member change my TB at his house. On startup the engine was louder than normal, making a metallic sound, and putting out a good amount of smoke, I was told to turn the engine off, we looked around and started it again, this time the timing was checked, but I can't remember the exact numbers. We readjusted the timing slightly and started the engine, the timing was checked again, but I can't tell you the numbers exactly. This time the metallic sound was gone, but the engine was running louder than normal. I was told to drive a couple miles to warm up the engine so we could fine-tune the timing afterward. I got a few houses down (and up to 20-30 mph) before the engine started making a louder sound and lost power. At this point I put it in reverse, turned around and almost made it back before it felt like something give away and the engine stopped abruptly and the car coasted a few feet. We pushed it back into the garage because it wouldn't turn over and tried to pull the crank manually but it wouldn't move past a certain point. One cell was thrown that had something to do with injection, but I don't remember exactly which one. Then we pulled the valve cover. One valve stem was sticking up .5-.75 inches with the lifter? lodged under a well-eaten cam lobe, everything else looked fine. The TB changer felt that since the engine ran and only one valve broke that a valve spring or keeper broke to cause this damage (i.e. mechanical failure unrelated to the TB change). We put the engine compartment back together and left in the new TB parts plus new air and fuel filter (i.e. not being dishonest and covering our tracks). I called a tow truck and had it taken to the nearest dealer for tear down and diagnosis. I was told that he knows the belt was installed correctly and that the damage was not due to a timing issue, none the less he felt bad and said if this doesn't get covered I can buy the parts for a new head and he'll repair it. I was also was not charged for the TB change.
The dealer asked about the new Tbelt they found. I told them the belt had just been changed, they immediately said the engine was out of time and would not warranty the damage. At this point all they did was pull the valve cover. I asked, “If you tear the engine down any further would there be any evidence that would lead to a mechanical failure instead?” The response was no! At this point I was quoted $640 to do a complete tear down and I was already in for $200+. I gave the ok to finish. Further investigation showed one broken valve that punched a hole through piston #2 and scored cylinder #2 (i.e. my engine is toast
) The other valves looked good and no apparent damage was found on the other pistons, although I don't know how closely they looked. No other damage was noted, the condition of the valve spring is unknown as it wasn't extracted, but it gave resistance on whatever metal piece the tech was pushing on.
I showed up the next day to see the damage and argue the TB replacer's theory. The Service manager first asks why in the world would I have my TB replaced so early? (This was also the opinion of the shop forman) I responded, "40K is when it is supposed to be changed. When do you think it should?" You'll love the response, 105K!
He further added that I should have received a letter from VW explaining this change. Pissed, I responded, "Do you know anything about a TDI engine." (Oops, but the guy has to be very ignorant about TDI's, remember he's the SERVICE MANAGER) Anyway we argue, look at the damage, I bring up countless times, why did only one valve break and my engine run for as long as it did if the timing was off. His answer is that he has seen several engines with similar damage due to bad timing. I also ask if he had proof the engine was out of time. He said, "No, but I don't need proof." Further he added that since the engine was DOA and the TB was just changed it was in his opinion that the engine was out of time (i.e. enough proof for him to deny my warranty claim). While talking to the service techs he ran off to call the regional rep and gave his story. My conversation with the service tech's revealed that the damage present could not have happened if the engine ran. (i.e. one valve could break and cause the engine to stop right after start up, but not run for any extended period of time) I brought this up with the service manager and he said that he doesn't believe I was able to drive my car and once again he doesn't have to prove his assumption. I was also told that the regional rep agreed with the service manager after a 5-minute conversation without inspecting the engine himself. VW customer service also agrees with the dealership.
Now I'm stuck with a blown engine, a shut case, nobody at VW that will hear my story, and the person that changed the belt insisting that an unrelated mechanical failure caused the damage.
Option 1: The dealer quoted $4800 for a rebuilt engine complete with TB and diagnostic fees. Maybe a little more for some odds and ends. I would have a 12mo/12K warranty. No option for a new engine. I am in for $400 for the diagnostic charge (they dropped the fee since they just tore it down $640 was to put it back together). The day before the service manager showed me a new engine could be installed for $5200 (with some wiggle room for price) and there might be a possible reman for less (estimated $1000 less), either way I would get the remainder of my 100K warranty back. I just talked to the Service Manager again and he insists that I would get the remainder of my warranty back.
Option 2arts Place offered me either a new long block, without injectors, turbo, and valve cover for $2495 +100 shipping with engine exchange or a new complete engine set up for the manual tranny at $2895 +shipping with exchange.
There's my story for this hell of a week. Where do I go from here? Will this complete engine bolt right onto my auto tranny? Do I just need to transfer the injection pump and keep the larger injectors? More power would be one bright spot from this ordeal. Since my engine warranty is gone, why the hell not?
Luckly, my in-laws have an extra junker available for a second car and they may be able to arrange for transport of my car, but my apartment complex won't let me do any work on it or store it.
Before we get started: My car is a 2001 Golf GLS Auto with approximately. 38500 miles. No mods ever done to the engine, religiously changed with Delvac 1/CAT oil at 10k intervals. TB kit purchased from Diesel Geek with all the correct part numbers.
(Just to let you know I am not a mechanic and all I can do is present what I remember being told the best I can)
This Saturday I had a respected TDI member change my TB at his house. On startup the engine was louder than normal, making a metallic sound, and putting out a good amount of smoke, I was told to turn the engine off, we looked around and started it again, this time the timing was checked, but I can't remember the exact numbers. We readjusted the timing slightly and started the engine, the timing was checked again, but I can't tell you the numbers exactly. This time the metallic sound was gone, but the engine was running louder than normal. I was told to drive a couple miles to warm up the engine so we could fine-tune the timing afterward. I got a few houses down (and up to 20-30 mph) before the engine started making a louder sound and lost power. At this point I put it in reverse, turned around and almost made it back before it felt like something give away and the engine stopped abruptly and the car coasted a few feet. We pushed it back into the garage because it wouldn't turn over and tried to pull the crank manually but it wouldn't move past a certain point. One cell was thrown that had something to do with injection, but I don't remember exactly which one. Then we pulled the valve cover. One valve stem was sticking up .5-.75 inches with the lifter? lodged under a well-eaten cam lobe, everything else looked fine. The TB changer felt that since the engine ran and only one valve broke that a valve spring or keeper broke to cause this damage (i.e. mechanical failure unrelated to the TB change). We put the engine compartment back together and left in the new TB parts plus new air and fuel filter (i.e. not being dishonest and covering our tracks). I called a tow truck and had it taken to the nearest dealer for tear down and diagnosis. I was told that he knows the belt was installed correctly and that the damage was not due to a timing issue, none the less he felt bad and said if this doesn't get covered I can buy the parts for a new head and he'll repair it. I was also was not charged for the TB change.
The dealer asked about the new Tbelt they found. I told them the belt had just been changed, they immediately said the engine was out of time and would not warranty the damage. At this point all they did was pull the valve cover. I asked, “If you tear the engine down any further would there be any evidence that would lead to a mechanical failure instead?” The response was no! At this point I was quoted $640 to do a complete tear down and I was already in for $200+. I gave the ok to finish. Further investigation showed one broken valve that punched a hole through piston #2 and scored cylinder #2 (i.e. my engine is toast
I showed up the next day to see the damage and argue the TB replacer's theory. The Service manager first asks why in the world would I have my TB replaced so early? (This was also the opinion of the shop forman) I responded, "40K is when it is supposed to be changed. When do you think it should?" You'll love the response, 105K!
Now I'm stuck with a blown engine, a shut case, nobody at VW that will hear my story, and the person that changed the belt insisting that an unrelated mechanical failure caused the damage.
Option 1: The dealer quoted $4800 for a rebuilt engine complete with TB and diagnostic fees. Maybe a little more for some odds and ends. I would have a 12mo/12K warranty. No option for a new engine. I am in for $400 for the diagnostic charge (they dropped the fee since they just tore it down $640 was to put it back together). The day before the service manager showed me a new engine could be installed for $5200 (with some wiggle room for price) and there might be a possible reman for less (estimated $1000 less), either way I would get the remainder of my 100K warranty back. I just talked to the Service Manager again and he insists that I would get the remainder of my warranty back.
Option 2arts Place offered me either a new long block, without injectors, turbo, and valve cover for $2495 +100 shipping with engine exchange or a new complete engine set up for the manual tranny at $2895 +shipping with exchange.
There's my story for this hell of a week. Where do I go from here? Will this complete engine bolt right onto my auto tranny? Do I just need to transfer the injection pump and keep the larger injectors? More power would be one bright spot from this ordeal. Since my engine warranty is gone, why the hell not?
Luckly, my in-laws have an extra junker available for a second car and they may be able to arrange for transport of my car, but my apartment complex won't let me do any work on it or store it.