VW TDI 204 HP Bi-Turbo reliability.

[Visio 3000]

Hello, I just came out of the servicing with my Cali 204HP, while I was in the workshop I saw a Cali 204hp bi-turbo (like all the 204) with the engine removed.. Asking the chief mechanic about the nature of the issue, he told me the a lot of these engines have to be replaced, or seriously overalled, starting as earlier as 100,000 Kms. It goes without saying that the warranty coverage is long passed, thus resulting to severally impacting the vacation budget. Is it something which is known or an exaggerated view of that dealership in Luxembourg?

 

[Beeechke1]

Sounds like the issue discussed in the this thread:-

Oil Comsumption / Engine Problems with 2010/2011 Cali's

My 2010 180 DSG...51000 miles. Last few trips (it's hardly been used last few years) it's using oil...last couple of trips it's gone from full dipstick to nothing on dipstick and oil warning light in approx 350 miles....expensive but is this undue cause for concern ? Anybody else for similar...

vwcaliforniaclub.com

 

[CALI FATE]

When you put a highly tuned / lowish capacity, twin turbo engine with complicated emissions technology into an overloaded builders van - i think you are asking for trouble. Dont get me wrong, they are tremendous to drive, especially with DSG and 4 motion, but there is too much to go wrong for me. Keep it simple and keep your fingers crossed - and keep a tow rope in the boot in case you get stuck.

 

[Visio 3000]

Thanks Cali Fate, you're most probably right small size engines with high torque cannot compete with a 4.2 L 8 cylinders, the CO2 legislations didn't help on reliability. Answer is: go electric!!!

 

[TripleBee]

Thanks Cali Fate, you're most probably right small size engines with high torque cannot compete with a 4.2 L 8 cylinders, the CO2 legislations didn't help on reliability. Answer is: go electric!!!

Good luck with your reliability.

 

[Legin]

Its likely referring to well the known exhaust gas cooler wrecking your engine issue started with 180 Bi turbo engines. Its nothing to do with the power produced. Current 204/199 have a different cooler like the 150.

 

[tuono001]

You said electric, I'd like this.

 

[Visio 3000]

Its likely referring to well the known exhaust gas cooler wrecking your engine issue started with 180 Bi turbo engines. Its nothing to do with the power produced. Current 204/199 have a different cooler like the 150.

Thanks Legin, would you imply that the issue is related to the gaz cooler?

 

[Visio 3000]

You said electric, I'd like this.

Thanks tuono001, back to the future... clever to install the Tesla accus!!!

 

[Legin]

Thanks Legin, would you imply that the issue is related to the gaz cooler?

This is the issue. The issue is Auminium Oxide from the drgaradation of the alloy cooling fins.


Some more EGR autopsy pictures from the TX forum for your viewing pleasure.

This first set is a C cooler from 2012 after approx. 80,000 km. The owner had no oil consumption issues but changed it as a precaution. It has been cleaned by bead blasting.

This second set is quite interesting, taken from a mid 2012 vehicle at 78,500 km. A non-suffix cooler, also changed as a precaution, with no EGR failure. It has been quickly cleaned up by brushing. The condition is quite good, which makes me think that the the driving profile (style and distance) may be a factor.

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[2into1]

I'm not sure it's wise to conflate the already controversial issue that hits some 180 engines with an isolated 'chat' about a different 204/199 engine.
As far as I know, there isn't a link, and the OP didn't suggest he'd been told there was.

 

[Legin]

Wise or not its good to explore facts for informed decision. In my case before I bought a 199 (which is basically the same as a late 204 with some software mods) VW Guru confirmed the change of recycle cooler to 150 design so I was then happy that the later engines dont run the same risk as the early ones. Each individual can evaluate the potential of the risk.
The main reason on my part was to highlight this differentiation.

 

[2into1]

Wise or not its good to explore facts for informed decision. In my case before I bought a 199 (which is basically the same as a late 204 with some software mods) VW Guru confirmed the change of recycle cooler to 150 design so I was then happy that the later engines dont run the same risk as the early ones. Each individual can evaluate the potential of the risk.
The main reason on my part was to highlight this differentiation.

So given you've been told that the 204 / 199 cooler is completely different to the 180 cooler, I'm puzzled why have you filled a thread about the 204 / 199 engine with details of the failing 180 cooler?

There are several threads about the 180 problem where your detailed photos would be helpful. Sticking them here will just confuse potential 204/199 buyers.

 

[Legin]

So given you've been told that the 204 / 199 cooler is completely different to the 180 cooler, why have you filled a thread about the 204 / 199 engine with details of the failing 180 cooler?

There are several threads about the 180 problem where your detailed photos would be helpful. Sticking them here will just confuse potential 204/19 buyers.

Simple. Because the first and subsequent posts could concern folk that because they have a 204 or are thinking of buying one its about to bite the dust and this is because it produces too much horsepower.
Im aware some early 204 engines suffered high oil consumption but personally unaware if this was a cylinder tribology issue (talk of torque plates for honing) or was the 180 cooler carried into some 204,s I dont know maybe VW Guru could enlighten us.
The photos are lifted from a thread in this forum and not my handywork.

 

[2into1]

I give up. It just seems almost intended to conflate two issues you've satisfied yourself are different. I'll leave it there.

 

[Legin]

May or may not be different my mind is still open and certainly not a done deal that they are different. It appears you have contributed nothing substantive other than its unrelated so best dropped. I will join you in a give up.

 

[Visio 3000]

OK OK.... I'm still waiting an answer on my initial question: Is the 204/199 a reliable engine or not? Does it fail after 100K Kms (65K miles). Not isolated case but statistically supported facts. Many thanks in advance.

 

[WelshGas]

OK OK.... I'm still waiting an answer on my initial question: Is the 204/199 a reliable engine or not? Does it fail after 100K Kms (65K miles). Not isolated case but statistically supported facts. Many thanks in advance.

Who knows. My 180 biturbo is a few miles short of 90,000 miles/5 yrs. Oil Consumption 250mls over 15,000 miles.

 

[2into1]

OK OK.... I'm still waiting an answer on my initial question: Is the 204/199 a reliable engine or not? Does it fail after 100K Kms (65K miles). Not isolated case but statistically supported facts. Many thanks in advance.

I suspect there are only a couple of 204/199 engined vans on this forum that have done 65k miles, so we are not in a good place to advise you. Cali mileages tend to be below average and the engine only dates to 2016.

 

[motacyclist]

As with any modern complicated expensive vehicle, make sure you have a good warranty!

 

[Sp0_0k]

I suspect there are only a couple of 204/199 engined vans on this forum that have done 65k miles, so we are not in a good place to advise you. Cali mileages tend to be below average and the engine only dates to 2016.

Close to 75k miles here. Still half a year of warranty. The engine keeps making lots of new noises each year There were some minor issues fixed within warranty so far.

 

[Phoenix387]

As with any modern complicated expensive vehicle, make sure you have a good warranty!

Visio 3000: To answer your original question, yes, there is an issue with the 204bhp engine. It relates to the egr cooler and loss of coolant. There is plenty of info out there about the flaws in the application and function of egr valves and their role in meeting emissions regs, so i don’t intend to address it here.

We have a 2018 DSG vehicle with this engine and it has just had a new egr valve and cooler fitted at 19k miles as all the coolant ended up in the engine. Luckily, it was caught in time before the engine was destroyed. It was only thanks to the prompt action of our conversion company NewWave Conversions and their previous experience of identical faults with these engines that saved us from having our engine destroyed. All covered under warranty after a bit of pressure applied to the local VW dealer to get it sorted. From what I can glean from my own research, there appears to be a faulty batch of egr coolers out there that fail early on in the life of the engine. Early symptoms (which we didn’t spot), include excessive running of the cooling fan after the engine has stopped, even after short journeys and progressively worsening coolant loss. This is easily identified as there is no evidence of leaks in the engine or underneath the engine.

We have since been advised by an independent VW specialist to only use good quality diesel fuel (shell v power/bp ultimate etc...), add a good quality engine cleaner to the tank every 2000 miles, and most importantly, take the van off the long life service intervals advised by VW and ensure the oil is changed every 6k-8k miles depending on the type of driving you do. They also suggested blanking off the egr and remapping the engine once the engine is out of warranty to avoid many of the issues that arise from the standard engine map which is only programmed for EU emissions cycles.

Hope this is of use.

 

[Visio 3000]

Many thanks Phoenix387, a lot of good advice. I do the oil change at lower interval (8K miles) and I tank only premium Diesel without knowing it could also improve the EGR cooler!!! As far as the remapping of the engine is concerned, would you have more detailed info on how it can be made. Thanks.

 

[Rodney]

Touch wood, mine has been ok so far, but only covered 36000 in three years, used very little oil in that time, just had is second oil change as per system asking for one.bur as pervious comment, I have extended the warranty just in case.

 

[kave]

My 204 HP has 70000km, no oil consumption at all. I am always running in according to motomans instructions which seems to help.