The 3.0 TDI engines were introduced in Volkswagen, Audi, and Porsche cars in 2004.
The first-generation units (EA896) were the least problematic engines of the VAG group.
In the following years, subsequent versions of these engines appeared, EA897 (2010)
In the following years, subsequent versions of these engines, EA897 (2010) were the least problematic engines of the VAG group, and EA897evo (2014).
The modifications were aimed at reducing emissions to meet European Union standards.
Unfortunately, in practice, it turned out that such changes have a negative impact on the lifespan of the engines.
Some defects, such as knocking camshafts and clattering oil pumps, manifest after just a few thousand kilometers and are repaired under warranty in authorized services.
Unfortunately, if the owner did not report the fault before the warranty period expired, they must then repair it at their own expense.
During operation, the cooperating elements within the engine must be properly lubricated.
What does properly lubricated mean?
Above all, oil must precisely fill the gaps between the moving parts of the engine that work together. To achieve this, it must be supplied to these places under the appropriate pressure.
If these parts come into contact with each other without the intermediary of oil of the right quality, the seizure process begins. Once this process starts, it usually intensifies rapidly. After intense heating, the parts melt into one mass.
Engines seize due to:
The reason for the lack of proper lubrication in EA897evo engines is too low oil pressure.
The inappropriate quality of oil is caused by dilution of engine oil with fuel.
Monitor the condition of the oil in the engine. If the oil level rises, it means that fuel is getting into the oil.
Then immediately go to a service to determine and repair the cause and change the oil.
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 3.0 TDI EA897evo 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.
The reduction of oil pressure at low engine RPMs was intended to cause less energy consumption needed to create such pressure. The method to reduce the power required to drive the oil pump is by using a pump with adjustable output controlled by the engine computer.
Less energy consumed by the oil pump was expected to translate into improved emissions.
This entire strategy was implemented to meet the EURO 6 emission standards.
This is probably self-explanatory.
Our service receives Audi and Volkswagen 3.0 TDI vehicles equipped with a variable output oil pump, in which engines have seized after tens of thousands of kilometers!
The overhaul of such an engine costs from 30 thousand PLN upwards, depending on how severely it seized.
A new 3.0 TDI engine, without equipment, costs depending on the model from 55 to 91 thousand PLN.
To this amount, of course, you must add the cost of engine replacement and related materials, and often also the costs of regeneration or a new turbocharger.
The cost of this repair at an authorized service center exceeds 100 thousand PLN.
Check if your car has such an engine. Read the engine code from the sticker.
You can also provide us with the VIN of the car, and we can check which engine is in it.
If you have the EA897evo engine and no one has previously adjusted the oil pressure settings, your engine is certainly at risk of seizure due to too low oil pressure.
Check what the oil pressure is in your engine.
You can read this with any diagnostic tester.
Raising the oil pressure is done while you wait (it takes about half an hour).
The above video shows how we do it.
By raising the oil pressure, you will save your engine from seizure and huge repair costs.
Equally important as the correct oil pressure is its viscosity (quality).
If engine oil is diluted with fuel, such oil will not provide proper lubrication for the engine, leading to its seizure, just as in the case of too low pressure.
The most common reason for fuel to get into the oil in these engines is faulty injectors.
Another possible cause is too frequent regeneration of the DPF filter (more on that in the next chapter).
Faulty injectors, providing incorrect dosage or improper spray, can lead to engine seizure or piston burnout in a very short time through oil dilution.
Therefore, during every engine overhaul or replacement, we will test your injectors on a professional test bench. We will also check and clean the DPF and SCR filters.
If your injectors are functional - i.e., they pass the tests positively, the machine will generate new codes for them, and they can be installed in the overhauled or new engine.
In our service center, we have a professionally equipped workshop for the regeneration of commonrail fuel system components. We test and regenerate injectors and fuel pumps.
The Diesel Particulate Filter (DPF) and catalyst are other components that, according to Volkswagen's instructions, should be replaced along with a damaged engine. This component could have been the cause of engine seizure.
How is this possible? Why does it happen?
As is known, there are two possible causes of seizure in 3.0 TDI EA897evo generation engines. These are too low oil pressure and dilution of engine oil by unburned diesel fuel.
Fuel can appear in engine oil in two situations.
The cost of a DPF for 3.0 TDI, depending on the vehicle model, ranges from 19,749 to 23,859 PLN.
In our service, we offer the regeneration of this component for 615 PLN.
The service is performed using a professional machine from the Swiss company FFSolution.
Regeneration restores the efficiency of DPF filters up to 98% and catalysts up to 100%.
Do you have questions about engine replacement or repair?
We will help you make a decision
Street Kolonia 19
43-430 Skoczów
