Anyone had problems after a remap?

[Transporter]

Of course we don't see the engine, we won't be able to hear it how it was running just after the tune, but it just doesn't add up. The engine failed too soon after the tune and without the warning (as long as the driver was a bit observant). The VW dealer that is not willing to find the truth cause why the engine failed, just being happy that they can blame the failure on something else.

How ever the title of the thread is "Anyone had problems after a remap?", and so far no one came forward that he would have the failure of the TDI engine similar to this one and in such a short time.

If it was me, I would be asap collecting from the dealer the failed components, getting all other evidence to build the case, and the dealer would be the first one to know it, should I have no choice but to leave my car in their mercy.

[Naresh]

Of course we don't see the engine, we won't be able to hear it how it was running just after the tune

Hi Transporter I did record a video showing the engine noise on the day I first discovered it. This was day 5 after the remap and only 70 miles of driving (have now confirmed this as the total distance travelled). Since the map I only did one "spirited" drive with the tuner to check the difference in power/torque but after that it was all conservative driving as I use the vehicle on school runs. No warning lights every appeared on my dash - that's what surprised me. But I understand that if a tuner changes the limiting parameters on the ECU then no warning lights would have appeared? Is that correct? If so that could be confirmed by a VCDS scan surely to check the error log files.

Have also just got back from VW after taking some more pictures. I will up load them later.

[Naresh]

Ok I have now uploaded the pictures taken earlier. I now realise the tiny brass fragments shown earlier were sitting in the engine sump cover. Another mechanic who was there told me it's likely they came from inside the piston head where it meets the con rod - is that possible? Could that be a mechanical defect? As for oils - the car was serviced by this same dealer in December 2012 and 1,400 miles ago. Before taking the car into them I checked the oil level and it was fine.

Anyway, here are the pics............

[Transporter]

How is the condition of the other 3 con rods bearings? If they're in perfect condition, then ask the dealer how he can explain that the only one cylinder failed? The tune affects all cylinders equally and you should see the similar signs of excessive wear on other 3 (because it happened so quickly). If not then I think that the lubrication failed in that engine.
How was the oil filter?
Was the coolant level always OK or were there some top ups needed to keep the level up?

It would be an interesting experiment after repairing that engine to leave the tune in there and observe. And, if everything would be OK after 15,000km get the oil sample tested and go back to that dealer for the refund if you'd pay for the repair.

How many oil changes did you have in total?
How long are your usual trips? (driving under severe driving conditions?)

[parso_rex]

We need more pics, I'm with transporter plus I still find it really hard to see how a tune with stock hardware could kill the bottom end in a diesel leaving everything else unscathed. Turbo yes I can believe that but the bottom end I can't see how you could kill bearings in such a short distance for that matter at all.
I might ask some of my counterparts OS tonight and see if there is some logic in it all.

[Transporter]

agree, plus within 100 miles in the winter conditions?

[Naresh]

Yes please any advice would be useful. What more pics would you like as that's all I could get. The car is up on the ramp and could not be moved. The mechanic is back from his course today so I'm assuming they will recommence the job today pending parts. I am told by VW HQ in the UK that they won't back down in this case due to the remap and I feel they've been through a similar scenario before!

Only this piston was removed and I'm sure the main block is still on the car hence not being able to see them. All oil and coolant plus filter was done during the last service 2 months ago and the previous service before that was 12 months before that.

My usual drive is approximately 30 miles a week for the school run and work commuting. I also do a 200 mile motorway drive once a month too.

Standard VW protocol is to replace the components and not repair hence the cost but like you guys I'm pretty shocked and angry at the extent of damage caused. I've been advised taking legal action against VW will not work and that I have to go after the tuner now who as you know simply wants to wash his hands of it. It's not as if it's just the cost of the remap I'm losing - that I could stomach and put down to a bad experience. I'm talking £5.5k which is going to hurt me for a long time!

[h100vw]

agree, plus within 100 miles in the winter conditions?

Pretty suspicious if it has only done one bearing that bad. My first thought was oil pressure? Although maybe the bearing was duff from manufacture and was destined to fail pretty soon anyway?

Gavin

[h100vw]

If you're paying, then you can dictate what VW do. Full engine or fix that one, it's your choice. They like the engine because it's fast for them.
As it's still unclear what failed though, it's not the right time to make the call.

What are the other big ends like? They can just take the caps off, no need to pull the piston out and add 3 more sets of rings to the job.

Gavin

[Transporter]

For sure, any good mechanic would check all the bearings, remove the pistons and check them as well when the engine is already open, since it's not that much of the work and the result and reliabilty of the repair depends on that all the affected components are inspected and replaced if needed.

Because, if the engine fails second time and possibly in short time after they've worked on it, it won't look good and they workmanship would be questioned.

Of course they will most likely use the same excuse that the engine was tuned before and they just couldn't xray every component, and because of that I would want to start with the new engine and have it in writing that they will warranty it fully. Otherwise, you could be just wasting your money with them.

I'm not saying that's why the engine failed, but your trips are quite short and you should change the engine oil and the filter every 6 months. If you drive 5 times per week and total only 30 miles and then 200 miles on the weekend. The soot in the oil will acumulate and won't get boiled off like the polutants from the petrol engine when you take your car for a longer drive.