TDi engine failure @ 70mph

[Tricky69]

Bastard car!

Just recently got it running sweet. Replaced injectors resulting in + 10mpg on a run and much better fuel economy around town with a lot more power as well. Passed the MOT last week with some minor work being done, so all was looking good.

2 days back, driving back from Wales to Kent when all of a sudden the cabin filled with smoke, instant power loss and oil warning messages flashing up. All of this in the middle of the Severn Bridge at 70mph!!

Popped the bonnet to ensure there wasn't a fire, only to see smoke/steam bellowing out from rear of engine for the whole width of it at the rear. Water was being lost, froth around the filler cap and absolutely no compression to start it again. Water and oil were checked at start of journey and both were fine. Got it home (eventually) at 10.30pm via 3 different recovery trucks. Looked at it today and engine still smells burnt with water being lost out of back of engine somewhere.

What are the chances it is just the head gasket which has blown in style?

Debating whether to sell or repair it now. 2004 reg 115bhp ghia model with MOT to 15/08/18 in pretty good order/spec, so what's it worth as spares/repair?

[Tricky69]

oh, and mileage is just 129k, 6 speed manual.

Thoroughly disgruntled as I have upgraded the dash to the full LCD middle section, centre dash to the black fascia for the sat nav MFD, new caliper, brakes, new interior door handles, DVD headrests, recent new exhaust, wishbone, tyres, drive shaft, etc.

Did I say it is a bastard car?!?!?!?

[johnnyroper]

Got to be honest that sounds more than just head gasket to me,more like the head is terminal. I think at best replacement head is needed but without stripping it you will not know full extent of damage or what has actually caused it.

[Tricky69]

Going to start stripping it tomorrow and see how much damage there is, but yes, I agree there is probably more than just a head gasket damaged.

I have sourced a replacement engine (AUY lump installed, AUY lump sourced from another Galaxy), but the reason that Galaxy was broken was because it was auto and the box was knackered.

Since mine is manual, is it pretty much a straight replacement once the flywheel and clutch have been swapped across?

Cheers.

[bigjeeze]

I changed my AUY engine a year or so a ago for an ex auto ( mine being manual) - and yes you just need to change the flywheel etc - I am not sure if there is any difference in the turbo etc as I used my original ones. But it all fits and works perfectly.

[johnnyroper]

As above swap flywheel and clutch over.
Only other difference is mapping but that's not an issue as you will be retaining your ecu.

[Tricky69]

Cheers guys.

Also, is it easier removing engine out the top once everything stripped out, or drop it out from underneath?

[Mirez]

Having done a few now, by far the easiest way is to take the front end off and bring it out there, it takes about an hour to remove (longer if you've not done it before) but gives the best access possible. You'll be draining the AC, Coolant and PAS fluid anyway so its actually not much more work.

Pulling it out the top is next to impossible because the engine is recessed under the scuttle/dash so the opening is only just big enough. Removing from the bottom is easy-ish if you have a 4 post lift but otherwise its awkward as you need a good amount of clearance (these engines are reasonably tall).

[Tricky69]

Cheers Mirez. Just read another thread about engine removal from the front which you posted on and yes, out the front looks the best option. So many fiddly bits to get sorted! I remember doing engine changes on my old mk1 Escort in less than 2 hours with everything done!

[Tricky69]

Well, I've finally got a replacement engine installed in the car. Had to wait for a new engine hoist to be delivered, then a new cam belt kit and water pump and finally a new clutch and flywheel as the dual mass flywheel had a rounded off thread when mounting the clutch plates to it! Opted to go for a single mass flywheel and clutch kit.

Got the engine in the car yesterday and finished off the wiring etc this morning. Stuck the battery on, turned it over a couple of times then it fired up, sorted!

Well, not quite ...... Had it running a few seconds (sounded good) then a huge puddle of oil had formed under the car and oil cascading down the back of the engine. WTF!! I grabbed an old duvet cover to start soaking up the oil and wiped down the back. It was only from looking under the car I saw a grinder mark cutting into the oil feed pipe to the turbo and the nearby metal pipe for coolant. Flipping breakers yard! Thankfully I have a spare from the engine I took out, so a job for the weekend no doubt. Shame I couldn't see it while engine was out as that would have made the job a lot easier.

Whilst putting it all back together, I noticed some play in the intermediary drive shaft, so got a new one being delivered soon to replace it all. No point bodging over a few things after all the other new items going on the car!