Seizure is a problem that can affect almost any engine – even those with a low mileage and operating normally almost until the last moment. Seizure can involve all moving parts of the engine that work together, however, in VW Audi 3.0 TDI engines, it is usually the crankshaft that seizes.
If the engine operates correctly, its moving parts are adequately lubricated, e.g., the piston ring does not directly contact the cylinder wall, the crankshaft does not touch the bearing shell, etc. – between these components, there is a thin layer of oil film which reduces friction.
However, if this layer disappears and these parts come into direct contact without the intermediary of a lubricant, even minimal, microscopic irregularities will cause friction to increase sharply, resulting in most of the mechanical energy (up to 95 percent) converting into heat. This condition is referred to as dry friction.
Once this process begins, it usually escalates rapidly. The more the rubbing components heat up, the more they expand (due to the action of high temperature), increasing the pressure and displacing the remnants of the oil film.
Even if the lack of lubrication was temporary, after the sudden heating of the components, the oil may no longer be able to reduce the friction between them. In extreme cases, so much heat can be generated that the engine eventually stops, due to the melting of the components of the crankshaft-piston system into one mass.
A seized engine, once cooled down, might start again, but it will never be suitable for normal use again, and each subsequent start will cause even more damage to its components.
Engine seizure is one of the worst scenarios for car owners.
Restoring a vehicle to full functionality after such a failure is a very costly process.
When we hear the diagnosis that the engine is seized, we face a very difficult decision:
An engine overhaul is a process that involves repairing or replacing damaged and worn parts to restore its functionality. The price of the service depends on which parts need to be replaced.
A quote is possible only after verification.
If the repair cost does not exceed 50% of the price of a new unit, then it is worth overhauling the engine.
Unfortunately, CRT CZV CZZ engines are very often so seized that it is not cost-effective to repair them.
In such a case, I recommend buying a new engine.
However, if you decide to buy a cheaper, overhauled, or used engine, demand a warranty for it.
Engines offered on the internet most often come with a short start-up warranty and no invoice.
If the seller does not provide at least a 12-month warranty, do not buy that engine.
An engine overhaul should be, and usually is, a cheaper alternative than buying a new unit.
An engine after a properly conducted overhaul should last at least 100,000 km.
Choosing to overhaul a third-generation 3.0 TDI engine at the VAG-EXPERT service, you will receive
12 months warranty with no mileage limit.
The cost of engine repair mainly depends on which parts need to be replaced.
To quote the repair, the engine must be disassembled and the condition of all its components verified.
An engine overhaul makes sense if its cost does not exceed 50% of the price of a new unit.
If in your engine the crankshaft or engine block or heads are so damaged that they are not suitable for regeneration, or if you need to replace the camshafts and lifters, then it is not worth overhauling it, as it would be cheaper to buy a new engine with a 24-month warranty.
We will help you decide whether it is worth overhauling your engine or better to replace it with a new one.
If you decide on engine regeneration - we get to work.
We regenerate the block and both engine heads.
In every engine, we replace: pistons with rings and all bearings, oil pump, all seals, sealing rings, screws: heads, main bearings, and connecting rods, all timing components (chains, tensioners, and sliders), and many other elements that, according to instructions, cannot be reused again.
We repair several Audis a week with seized third-generation 3.0 TDI engines.
Unfortunately, a significant percentage of these engines are not cost-effective to overhaul.
On average, in 7 out of 10 cases, customers opt to purchase a brand-new engine.
New CRT CZV CZZ engines cost 18734 € at authorized Audi service centers.
In our service, instead of these somewhat unsuccessful engines, we install units with the code DEN, which are an improved version of the aforementioned engines, and can be bought at VW dealerships as a new replacement engine for 13 481 €
At dealerships, these engines are made to order, and often you have to wait several weeks for delivery.
With us, they are always in stock, and we replace up to 4 units a week.
This is an example from a customer who was quoted 27 040 € for a replacement at an authorized service center, but paid only 15 850 € with us.
Why such a big difference in price?
The difference comes from the commercial policies of Audi and Volkswagen brands. CRT CZV and CZZ engines are intended for Audi (a premium brand), so they cost nearly 5 350 € more at dealerships than the DEN engine (which is for Volkswagen), even though they do not differ from each other.
Moreover, we sell these engines for 1900 € less than dealerships, and charge less for the replacement.
We have undeniable experience in engine overhauls and replacements. We have been in this business for 28 years. We have overhauled more than 300 3.0 TDI engines and installed about 160 such NEW engines.
Improper engine installation and failure to rectify faults in engine accessories that caused the original engine to seize will result in the failure of the new unit.
Replacing a seized 3.0 TDI engine is a process consisting of many tasks related to identifying and repairing or replacing engine accessories that caused its seizure, as well as components that were damaged as a result of this failure.
We determine the causes of engine seizure
The first thing to check is the injectors
An injector that fails the tests must be replaced. If it achieves a positive result, it receives a new Imei code, which must then be added to the car's control unit.
Next, the DPF is checked
The filter is tested using a professional machine from the Swiss company FFSolution
If the DPF is clogged, we attempt to clean it using the aforementioned device. If the cleaning process is unsuccessful, the particulate filter must be replaced.
The turbocharger is also checked
We test the turbocharger on a professional device, TurboTest by Cimat
The turbine is lubricated with engine oil, so it often seizes for the same reasons as the engine. If the turbine does not pass the test, it needs to be replaced.
This is another important procedure we perform with every engine replacement
It involves reprogramming the engine controller to achieve higher engine oil pressure, such modification significantly extends the lifespan of the new engine.
With every 3.0 TDI engine replacement, we clean the engine intake system components of carbon deposits
We replace accessory components contaminated with filings from the seized engine, which cannot be effectively cleaned, such as the oil cooler or oil level sensor. We use new seals for all transferred components. We replace the fuel and air filters, as well as the gas and oil in the air conditioning system.
This happens because the turbocharger is lubricated with the same oil as the engine. The turbine is particularly vulnerable to damage due to the very high speeds at which its rotor must operate.
According to VAG instructions, the turbocharger should be replaced along with the engine.
The cost of such a component at authorized service centers is 2570 €.
This recommendation arises from the fact that authorized services do not have the equipment to flush out filings from the turbine that may be there from the seized engine, nor to perform a turbocharger efficiency test.
Our service is equipped with a professional TurboTest machine by Cimat for testing the efficiency of turbochargers, so we test every turbine from CRT engines. It turns out that in 50% of cases, the turbo does not need to be replaced.
However, if the turbine turns out to be seized, unfortunately, it cannot currently be regenerated due to the lack of availability of spare parts.
In our service, a NEW turbocharger for CRT CZV CZZ engines costs 1140 €.
If you've encountered the misfortune of your CRT engine seizing, brace yourself for the costs.
This is an engine whose repair is very difficult and costly, and often simply not worth it.
You cannot repair this engine cheaply and well.
Beware of cheap offers! Trying to save a bit can lead you to lose much more.
Is 11 900 € for a NEW engine a lot?
With that amount, you receive an engine with an injection pump. It is an original Volkswagen product. All defects that occurred in the CRT, CZV, CZZ, and CVM engines from the first years of their production are eliminated in it.
You will get a 24-month warranty with no mileage limit on such an engine, and of course, a VAT invoice.
Then, is it worth spending about 7 000 € on a used engine?
Such engines are between 5 to 9 years old and "of course" are almost without mileage. Interesting?
Yes, they come from cars that the German retiree drove only to church. Do you still believe in such stories?
Most of these engines are offered with a short start-up warranty and without an invoice.
If such an engine seizes after a few months, it turns out you've thrown a significant amount of money away.
The same goes for engines that sellers call "refurbished" or "overhauled."
They too are usually offered with a very short warranty and without a VAT invoice.
Interesting why their sellers do not want to take responsibility for the "overhaul."
I think it's because they know very well that an engine after such an overhaul will not last very long.
See what happened to an engine purchased on Allegro after driving just under 1500 km.
If you don't want your story to end the same way, take advantage of our offer.
For 11 900 € + replacement costs, you will receive a NEW engine with a 2-year warranty with no mileage limit.
Do you have questions about engine replacement or repair?
We will help you make a decision
Street Kolonia 19
43-430 Skoczów
