VAG TDI 1.9 PD engine failures

[Zoobeef]

Mines a 130 bhp 2002 A4 1.9
Bought a year ago on 158k and has just gotten to 187k. As far as I'm aware everything is still original and it tows my trailer and track car like a tank

[Mr2Mike]

Zoobeef said:

Mines a 130 bhp 2002 A4 1.9
it tows my trailer and track car like a tank

Lots of black smoke, astronomical fuel consumption and a maximum speed of about 40mph?

[Fionad]

Yet another BXE casualty -
My '57 golf 1.9tdi put a con rod through the block today. My garage (lovely local independent) said their investigations today revealed it is a "known fault" with the BXE code engines and that even had it been serviced yesterday it's not something that could be picked up or predicted.

I had done 113,000 totally bill free miles (other than tyres, brake pads and servicing) so maybe should not be so cross but reading all these other cases means tomorrow I am contacting VW to complain. In the meantime I have found someone (global engines.co.uk) who will fit a recon head and block for £1350. Does anyone have any experience of them?

Thanks

[Fionad]

dbfan said:

I suspect you're stuck with the same engine - if only because of the onboard electronics. In theory, the new engine shouldn't fail for a while (I keep saying that to myself!!): I suspect that the variable interval servicing is a large part of the problem. I have no proof of that, but always change oil at around 7K intervals: I've only had my Golf for two years - 5000 miles - and was about to give it a second service. Unfortunately, it has 117K on it and only had three oil changes before I got it - and the service history is the best I've seen: it even includes wiper blades!

My remanufactured engine was £2106 (inc delivery and collection of the old engine)and has a year's warranty (inc labour). I also bought a new flywheel and clutch, cam belt kit, water pump, auxiliary belt and supplied oil and filters (about £700's worth of bits!). The garage found a broken back spring when they had sorted the engine, so I got them to do that and their bill was just short of £600 all in.

As my Golf is a Bluemotion, it is a little more "desirable" than an ordinary one, so the car should be worth about £5,500 - £6000 if I sell it privately (I doubt it is in the real world though!). My options were to scrap it and find £6K for another car (possibly a Volvo!) or spend the £3K+; make sure I change the oil much more often than VW say (at great expense) and make the car last a few years; or find an engine at the breakers and part exchange ASAP afterwards! I tried the last option first, but BLS engines seem to be sold before they arrive a the breakers and high mileage ones on eBay were £800+ delivery.

One warning though: check the engine supplier out before parting with money. One I saw on eBay was well known: they had been on Watchdog, reported to the RAC and Trading Standards! Mind you, the engine was a lot cheaper!!

Oh yes, a neighbour has just scrapped a 2.0TDI Mk5 Golf as the head had "gone" and he has bought a 2001 Peugeot 307(?) that has 140K on the clock and is as sweet as a nut!

Was it Global engines?

[silveroct]

Hi All,

another BXE died this week, my 57 Octavia, 90k miles.

So now to decide to scrap or replace with a recon, decisions decisions....

FIONAD - did you go with Globalengines in the end?

[mclwanB]

And another one bites the dust. Bear in mind replacement engine needs to be same engine code so would definitely go remanufactured- which should be ok- over second hand

[silveroct]

100% agree, 2nd hand is just too risky, so now trying to get recommendations on recon companies, any recommendations for those to go with or avoid would be very welcome!

[Fionad]

I went through first choice spares an Internet site/company that puts out your parts request to loads of car "dismantlers" . Bought a second hand engine with three months warranty from Charles Trent in Dorset. They have 5* feedback so hopefully ok. Very helpful guy on the phone (not a premium number) - engine was sent directly to my garage £1000 for the engine and £700 to the garage for fitting it including a new flywheel and a few other bits. It's running well and fuel economy has improved.

[silveroct]

Hi Fionad thanks, that's useful to know, will see what they can find for me.

[crossy67]

So has anyone ever looked at the BXE block compared to other engine numbers to see if they could be fitted? I find it incredible that VAG would produce so many different types of block all to reach the same end. Is it realistic to assume the blocks are all based the same but with extra machining done on some and not on others. For example, the Skoda has a hole drilled and tapped for mounting a power steering pipe to where the Golf doesn't need the pipe so they skip that part of the machining process?

Just trying to understand what the differences are and if it's possible to swap a BXE for something more reliable.

[masermartin]

crossy67 said:

So has anyone ever looked at the BXE block compared to other engine numbers to see if they could be fitted? I find it incredible that VAG would produce so many different types of block all to reach the same end. Is it realistic to assume the blocks are all based the same but with extra machining done on some and not on others. For example, the Skoda has a hole drilled and tapped for mounting a power steering pipe to where the Golf doesn't need the pipe so they skip that part of the machining process?

Just trying to understand what the differences are and if it's possible to swap a BXE for something more reliable.

My understanding is that the engine code applies to the engine and all its components as supplied, not just the block - the block in fact might be the same as some of the other engine codes, but some of the components used inside it might (probably will) be different. For another example, take the (rather ubiquitous) 1.8 t 20v where there were also a bunch of different engine codes. It's the same basic engine, but you can't get the 150 up to the same power output as a 180 or 225 with a simple remap, because they have different internals and ancillaries etc.

I am in no way an expert on this though! It does seem I'm OK with my '05 Bora 130 PD so far, 148k and still going OK, although it has got a bit noisier and less refined in the last 20k ...

ETA: it does seem like they've made a batch of 105's with chocolate conrods or poor bore lubrication though. As someone else said, hurrah for cost saving.

Edited by masermartin on Monday 20th October 13:26

[anonymous-user]

I'm sure I read somewhere that there is one other 1.9Tdi Engine code that you can replace a BXE with without issues. Ill try and find the place that I read it.

[crossy67]

Please do, I have been offered a Skoda very cheap but it needs an engine

[shred2bits]

Don't think you can fit another engine, I mean you can but labour would be ££££. Someone I k ow just paid 3k to have his bxe replaced, haven't talked to him much about it as it's a bit of a sore subject

[The Transplanter]

crossy67 said:

So has anyone ever looked at the BXE block compared to other engine numbers to see if they could be fitted? I find it incredible that VAG would produce so many different types of block all to reach the same end. Is it realistic to assume the blocks are all based the same but with extra machining done on some and not on others. For example, the Skoda has a hole drilled and tapped for mounting a power steering pipe to where the Golf doesn't need the pipe so they skip that part of the machining process?

Just trying to understand what the differences are and if it's possible to swap a BXE for something more reliable.

When VW (group) introduce a new engine they tend to initially over engineer them, and then relax specs as time goes on (what they can get away with)!

The BXE & BLS engine codes are the last of the 1.9 8v TDI's and are notorious for failure (im a VW specialist myself). I have personally seen many failures with these, im not sure for the exact reason for failure as they just go in the scrap as no none will pay for inspection/dignosis! But what I can tell you is; the Big end journals on these are smaller the type fitted in the 1.9's @ 50.6mm where as the strongest known 1.9's were 53.7mm

But there are other 1.9 PD's with 50.6mm journals that are not causing problems! So I can only imagine it is a material issue?!?! You can upgrade these engines with stronger aftermarket rods, but normally its to late once you have a gaping hole in the block!

Earlier (stronger) engines can be used instead, but you will need to talk to your local specialist to see if they will take that swap on as there are some differences. I would recommend either a ASZ or ARL engine codes, as these are the 130 & 150 bhp models with the larger journals and are virtually bullet proof in comparison

[Countdown]

How much money were VAG saving by shaving 3mm off the bearings?

Bonkers.

[Mr2Mike]

Countdown said:

How much money were VAG saving by shaving 3mm off the bearings?

Bonkers.

It's not just money, the smaller the journal diameter the lower the friction, and hence better economy. In any case it's not the crank or bearing which is failing so the journal size isn't really relevant.

[crossy67]

That's handy to know, I have access to a 130 bottom end of some form out of a golf.

[pstruck]

Just checked and seen that my wifes 2006 Octavia has the BXE engine. I had read a bit these failures before, but had forgotten and hadn't thought to check what ours was at the time. It's currently on 81k miles and has a very easy life. I see it had a new turbo fitted by a previous owner, but since we've owned it it has only needed routine servicing. Maybe it's time to move it on.

[Zoobeef]

What years did the BXE engines run?
My 02 reg A4 has a AWX engine in. Just passed 190k miles.