Engine Replacement Help!

[jb1998]

I have a 2003 Audi A3 2.0TDI which has just been diagnosed as having a cracked piston head  I have been told that to purchase a brand new part it will cost around £1000 for the part and then there's the labour to add on top. I have also been told from a different mechanic that I might be as well to purchase another engine and get that fitted instead of replacing the part itself. What would you guys suggest I do?

Another question I have got is would I have to get the exact same 140bhp engine as the one that is has now? I have seen on eBay a few 2.0TDI A3 engines that are producing around 180bhp standard, obviously my car only has a 140bhp turbo (this is a fairly new turbo, only been fitted around 2 months) so would this not work?

I am aware that I can pull this engine out of SEAT's and VW's etc so another option I have would be to purchase a spares and repairs car that has the engine I need which runs fine but has been smashed up at the back and take that engine?

I really don't want and don't have the cash to buy another car so would like to be able to get this one back on the road as cheaply as possible whilst at the same time not cutting any corners... Any help and recommendations would be appreciated!

[Audi Owners Club.]

HI Jonathan...welcome to the Forum

What are the symptoms for the cracked piston and ultimate failure of the engine?

Cheers  Trevor

[jb1998]

Hi Trevor, coolant was disappearing, there were no leaks from any of the pipes or from the radiator. Mechanic thought it might have been the head gasket that was the problem but when the engine was stripped they found the had gasket to be completely fine - piston head was sent off to a specialist who then after testing the part by pressurising it, diagnosed the problem as there being a crack in the piston head. 

[Audi Owners Club.]

That's an unusual one!   could imagine a liner cracking as this is quite common on some cars

 

[jb1998]

Yeah, I know 

Would you suggest I buy a cylinder head off eBay? Would that work instead of purchasing a complete engine? Or would there be other parts that would need taking from the other engine in order to fix my current one?

[Magnet]

Hello Jonathan,

Really exactly as Trevor says. A crack in a piston would not result in any coolant loss unless there was any other coolant associated issue with this engine. I think you may be well advised to get a qualified second opinion on this and have it explained exactly what is wrong here. Sending a piston off and getting it pressure tested!? Well that's certainly a new one on me! 

Cylinder head and pressure testing and finding cracks however, would make very good sense, and if this was at fault then a good replacement cylinder head should sort out the problem - assuming reference to a piston is incorrect. 

In summary, I would most definitely seek a second opinion before doing anything. 

Good luck with sorting it out and understanding exactly what the issue is.

Kind regards,

Gareth.

[jb1998]

Hi Gareth,

I have just noticed my mistake! I have been meaning cylinder head the whole time.. Stupid me (I'm no engine expert).

I think what I am going to do is purchase a cylinder head off eBay, my mechanic is going to get a head gasket set and cambelt and we should have the car built back up soon. 

Hopefully this will sort everything out :)

[Magnet]

Hello Jonathan,

No problem at all, it's just that I'm old enough to confuse myself! 

Re. a cylinder head off eBay, may I say without being pessimistic, that you could be buying your own - if you see what I mean. If it were me , I think I would try to get one which comes with pressure test having been done and ideally the mating surface skimmed to flatness. If you don't, you would be wise to factor in the cost of having these done, and I certainly would not recommend fitting a head without having it skimmed. 

You will probably realise that the lion's share of the cost (apart from the cylinder head itself) will be the labour cost, so I would ensure your mechanic uses good quality pasts, particularly the very critical timing belt and its associated parts. For me, I would only use Gates belts if you are not going to use genuine VAG parts. Another so important aspect is that if the water pump is being changed, I would recommend you don't, just don't , (in capitals!) use any aftermarket make pump otherwise you are leaving yourself more vulnerable to some catastrophic failure due to poor quality replacement parts. Worth spending once and wisely.

Good luck with it.

Kind regards,

Gareth.

[jb1998]

Hi Gareth,

Thanks for your advice. I have managed to get my hands on a head that's come out of an engine which was on around 50k miles. My mechanic is getting it pressure tested and then, if all is well, skimmed and then fitted. Obviously the head gasket is going to be done along with the cambelt (I'm sure he will use a good quality one) - I'm also getting the water pump done at the same time seeing as though the engine is already stripped down and you suggested it to be done.

I'll be sure to keep you updated and let you know how it's going.. Fingers crossed it'll be sorted soon!

[Magnet]

Hello Jonathan,

Sounds good and progressive, and fingers crossed its all going to work out well.

I cannot stress enough that the quality of the components used is of paramount importance, and sometimes leaving it to the mechanic may result in having parts which the local motor factors have in stock, which may or may not be what you want. Would I leave it to the mechanic to chose a brand of water pump or cambelt?  No I most certainly would not - I would insist he uses a main dealer one since the % on cost on the whole job will be marginal. For me, if not a main dealer belt, it would have to be a Gates one. The effect of fitting a substandard water pump in particular however, could be catastrophic. 

Not wanting to labour the point, but it's a bit like leaving someone to buy you a pair of trainers. You may well end up with a cheaper pair which just don't stand up to the wear you would expect. 

Hope this doesn't come over as being too dictstorial, but.... 

Good luck and kind regards,

Gareth.