On the 23rd of Novemeber my Greenline II was booked into my local dealers for a check up due to a flashing glow plug light coming on and going off, I thought just one of them new car glitches.

When the mechanic started the car he identified an unusual sound coming from the engine and he sent a sound clip off to Skoda. To me the car sounded no different to when I collected it from a different dealer ( better deal) just a bit louder due to the cold weather at start up.

It was decided as the model type was brand new the car was unsafe to drive and the dealers arranged with Skoda for a hire car, the courtesy car was collected by them from where I work and a hire care supplied - Zafira.

After further investigation and a full engine strip down they found main bearing 1 was failing and there was an unusual bloom in the cylinders. Looking at the bloom it looked like the pistons and the valves were coming into contact? As a result of the investigations Skoda have agreed to fully replace the engine.

I should get the car back by the 16th December subject to the fitting and testing of the replacement engine.

I know dealer service is expensive (certainly for my Citroen) compared to independent, but I have to ask myself would the fault with my car have been found by an indy?

On the 23rd of Novemeber my Greenline II was booked into my local dealers for a check up due to a flashing glow plug light coming on and going off, I thought just one of them new car glitches.

When the mechanic started the car he identified an unusual sound coming from the engine and he sent a sound clip off to Skoda. To me the car sounded no different to when I collected it from a different dealer ( better deal) just a bit louder due to the cold weather at start up.

It was decided as the model type was brand new the car was unsafe to drive and the dealers arranged with Skoda for a hire car, the courtesy car was collected by them from where I work and a hire care supplied - Zafira.

After further investigation and a full engine strip down they found main bearing 1 was failing and there was an unusual bloom in the cylinders. Looking at the bloom it looked like the pistons and the valves were coming into contact? As a result of the investigations Skoda have agreed to fully replace the engine.

I should get the car back by the 16th December subject to the fitting and testing of the replacement engine.

I know dealer service is expensive (certainly for my Citroen) compared to independent, but I have to ask myself would the fault with my car have been found by an indy?

Considering how new the car is I would expect the dealer to bend over backwards to help. Its good to see that your being looked after. Agreed to replace the engine ? I should ruddy well hope so. Some would throw the entire car back as unfit for purpose......I probably would. That said, you obviously like the car so with a new engine I hope you enjoy many thousands of trouble free miles.

Even the best manufacturers in the world have the odd duff engine. Maybe you have just been unlucky. Is that engine brand new for the entire VAG range ? Or has it been used in polos etc for a while ?

Not a good start for a brand new engine design.....

Not a good start for a brand new engine design.....

Is it completely new or just new to the Skoda ?

Engines go through thousands of hours of testing....just like the Rolls Royce engines did on the Airbus A380............

Edited 12 December, 201015 yr by raisbeck

It's completely new to VAG as far as I know. Good result to get the engine replaced, lets hope it's an isolated incident.

Considering how new the car is I would expect the dealer to bend over backwards to help. Its good to see that your being looked after. Agreed to replace the engine ? I should ruddy well hope so. Some would throw the entire car back as unfit for purpose......I probably would. That said, you obviously like the car so with a new engine I hope you enjoy many thousands of trouble free miles.

Even the best manufacturers in the world have the odd duff engine. Maybe you have just been unlucky. Is that engine brand new for the entire VAG range ? Or has it been used in polos etc for a while ?

I think I have been both unlucky and lucky. It looks like just a duff engine and normally they would just do a half replacement replacing the bottom part of the engine and the valves, but none were available so a new engine was authorised.

Plus if the valves and the piston heads were just coming into contact the engine could have blown at any time, possibly putting me and my family in danger.

I thought this engine had been in the Polo for a while now?

The problem with refusing the car now is getting a replacement, the trade in car and additional deposit. With a disabled child I am in a position where it would be extremely difficult if I had no car - we only have the one, rare these days.

Even with a dodgy engine I was getting a lot more to the gallon than my other diesel Citroen.

This sort of thing is very unusual indeed, and in your case sounds as if an oil way in the crankshaft main bearing journal is delivering less oil than it should. This would affect both crank bearing lubrication and piston and ring lubing. This could be due to the oil way being partially blocked, incorrectly drilled etc. That would cause the problems you have spoken about. Glad you are getting a new engine. If it's any consolation, a petrol engine probably would have seized up sometime ago as they are much more dependant on good oil lubing of the pistons and rings.

Good luck.

Edited 13 December, 201015 yr by Estate Man

This sort of thing is very unusual indeed, and in your case sounds as if an oil way in the crankshaft main bearing journal is delivering less oil than it should. This would affect both crank bearing lubrication and piston and ring lubing. This could be due to the oil way being partially blocked, incorrectly drilled etc. That would cause the problems you have spoken about. Glad you are getting a new engine. If it's any consolation, a petrol engine probably would have seized up sometime ago as they are much more dependant on good oil lubing of the pistons and rings.

Good luck.

Sorry for such a delay.

Got my car back last night and the warranty work shows a faulty crankshaft? and an update to the injector map in the ECU.

The only reason I got a complete new engine is they could not get a part engine, so Skoda had to cough up for a complete new one.

I asked about the ECU update and the service guy said they had only updated the injector map in the ECU not the ECU and the data stored would be kept?

I now have a very tight engine, much tighter than the old (faulty) one (even when first collected) and an ECU half way through its learning process, will the ECU now adapt to the new engine?

Raisebeck, as part of a good running in process I need to when the engine is warm get the engine revs up to 3000 rpm, how often and for how long?

Sorry for such a delay.

Got my car back last night and the warranty work shows a faulty crankshaft? and an update to the injector map in the ECU.

The only reason I got a complete new engine is they could not get a part engine, so Skoda had to cough up for a complete new one.

I asked about the ECU update and the service guy said they had only updated the injector map in the ECU not the ECU and the data stored would be kept?

I now have a very tight engine, much tighter than the old (faulty) one (even when first collected) and an ECU half way through its learning process, will the ECU now adapt to the new engine?

Raisebeck, as part of a good running in process I need to when the engine is warm get the engine revs up to 3000 rpm, how often and for how long?

I am no expert on running in however, if you just drive it normally without straining it at too low an rpm you will be fine. Also try no to sit at a steady rpm for ages like on a motorway run. Dont be afraid to rev it a bit as you go through the gears. Basically just work the engine without reving the hell out of it or pootling around. Always wait until its fully warmed up before you give it some beans !! If they asked you to use 3000 rpm then I would say just rev to this as you change through the gears. I wouldnt sit at these revs, just rev to it. The extra revs along with the boost that goes with it helps seat the rings in the bores.....apparently

You dont have to rev like this all the time. Just do it periodically as you drive. Honestly dont worry too much. It will be fine

Keep a bit more of an eye on oil consumption. Some say they can use a bit of oil in the early stages........mine never used a drop but its worth mentioning/.

I dont see the ECU as a problem. New engine, new ECU program. It will sort itself out as you drive.

Getting a new engine was the best result really. I wouldnt want a new car whose engine has been in bits outside of a clean construction environment.

Keep us up to date on how the new engine goes and the mpg you get.

Edited 18 December, 201015 yr by raisbeck

Hello Dempsek,

That's brilliant news. A new full engine unit is always nice, but ironically, it can often work out cheaper and usually quicker for the manufacturer to supply a brand new engine depending on where the new engine has to come from. This saves them having to pay the local dealer to prepare the old engine parts for rebuild and then do the actually rebuild into the new 'part engine' (which is usually just the engine block, no cylinder head, with pistons and crank only). Modern main dealers have very clinical workshop conditions to do this. A straight engine swap is always nice though and in your case obviously, the only way. Enjoy your new engine and be confident you should never ever have a problem like that again. You should find you will get better mpg's than your old engine once run in.

We had one of the first PD engines fail on us, not a pleasant experience at all. Well done to the dealer for spotting it. With major faults like that I have generally found VW customer service very good. In that case they gave us an autochanger as a good will. On our present Fabia they gave us the complete sun blind set. Probably worth a call to let them know what has happened to you.

We had one of the first PD engines fail on us, not a pleasant experience at all. Well done to the dealer for spotting it. With major faults like that I have generally found VW customer service very good. In that case they gave us an autochanger as a good will. On our present Fabia they gave us the complete sun blind set. Probably worth a call to let them know what has happened to you.

Thanks for that Black I will give them a call and se what happens.

So is the new engine any quieter/smoother than the old?

Also please dont forget to send the V5C back to the DVLA with the new engine number on it, otherwise come sale time it may cause you a problem.

Also please dont forget to send the V5C back to the DVLA with the new engine number on it, otherwise come sale time it may cause you a problem.

Thanks, I did ask the garage for the number and I will have to ask again.

So is the new engine any quieter/smoother than the old?

I am a bit deaf and when the engine is warm I cannot tell the difference between the two, when cold the new engine is a lot quieter than the old one.

I suspect due to the manufacturing faults the old engine in effect became loose very early on but was not producing full power. The new engine is defiantly tighter than the old one, and my mpg has taken a hit (still a lot better than the Zafira I was driving) then again it's only done 90 miles.

Thanks, I did ask the garage for the number and I will have to ask again.

If you check the engine for it's engine number, you will probably find it doesn't have one! This situation normally exists if the engine has been pulled from the engine production line, as yours will almost certainly have been. Engines are not normally stamped with an ID until being matched to specific models of car. If the engine is not being put into a specific car at the factory it doesn't get a number. Strange eh! Nearly all manufacturers used to operate in this way for all sorts of reasons. This used to be normal in my time as a tech, and unless anything has changed it still will be. If indeed your engine does not have an engine number, all you need is a letter from your dealer stating a brand new factory engine has been fitted on a particular date, and it does not have an engine number. You can then let DVLC know enclosing a copy of the letter for their perusal. If you can let us all know about this one it would be good...I'm curious to know if that's still how it's done.

ps. I've personally had a new Ford that required a brand new engine from the factory under warranty after 6 months and it came with no engine number, and I've had two brand new Toyota's that had new engines, again no engine numbers.

Edited 19 December, 201015 yr by Estate Man

I am no expert on running in however, if you just drive it normally without straining it at too low an rpm you will be fine. Also try no to sit at a steady rpm for ages like on a motorway run. Dont be afraid to rev it a bit as you go through the gears. Basically just work the engine without reving the hell out of it or pootling around. Always wait until its fully warmed up before you give it some beans !! If they asked you to use 3000 rpm then I would say just rev to this as you change through the gears. I wouldnt sit at these revs, just rev to it. The extra revs along with the boost that goes with it helps seat the rings in the bores.....apparently You dont have to rev like this all the time. Just do it periodically as you drive. Honestly dont worry too much. It will be fineKeep a bit more of an eye on oil consumption. Some say they can use a bit of oil in the early stages........mine never used a drop but its worth mentioning/.I dont see the ECU as a problem. New engine, new ECU program. It will sort itself out as you drive.Getting a new engine was the best result really. I wouldnt want a new car whose engine has been in bits outside of a clean construction environment. Keep us up to date on how the new engine goes and the mpg you get.

I agree with raisbeck, don't labour the engine at low speeds and don't hold high spoeeds for too long. The reason for the revs and boost helping to seat the rings is down to pressure. When you give the engine some hard work the pressures in the cylinders rise accordingly and it is this pressure that forces the rings tight up to the cylinder bores so that they rub together better and form a better seal, so helping the power output and oil control. Vary the revs and use full throttle regularly and you should be fine.

Ian

Having company cars I have never really had the time or the thought to think about the way I drive.

I never gave it a thought with my Citreon and had no problems.

It's just unsettled me I bought a VAG engined car and it has failed and I have become concious of the way I drive, I am sure it will pass.

Well the car is now 11 months old and on 8th of August injector no 1 failed with no replacement in country, got the car back and no 2 injector seal failed back to garage.

The car is currently with Skoda awaiting repair of seal 2 and replacement of injector 3 as it is badly scored if I am lucky I will get the car back tomorrow.

In the 11 months of running the car Skoda dealers have had it for nearly three months. Customer services say nothing but sorry, you have a hire car - blah blah blah.

I have now taken legal advice and am perusing VW finance services, I have been advised that because the car had to have a new engine within 6 months of supply under the consumer regulations the car was supplied faulty and under the supply of goods act a car has to be fit for purpose and of satisfactory quality which it is not. I have explained all repairs made to correct the faulty goods have also failed and am refusing the car requesting a replacement.

Sent three emails none replied to or opened (registered letter next) we will see what happens now, if it's like Customer services they will just ignore it with a smile.

PS advice given free by Skoda breakdown run by RAC.

It would be interesting to know if the replacement engine was a "complete" engine ( as fitted in the factory process) or was it a new "long block" engine that required most of the old engine ancillaries to be transferred over . If it was only a new long block, then the injector & injector sealing problems could have been "induced" by the dealer during the engine re-assembly.

Why would a new ECU fuelling map update be required ? What was wrong with old one ?

I think you have enough grounds to reject the car . One way to get Skoda customer services attention is to publish your problems and Skodas reaction to them on Twitter. Most big companies have people in their customer services depts whose only job is trawl Twitter to see any adverse company comments. They don't like any bad publicity and will quickly take action to correct it.

It makes sense to allow engine ( and oil) to warm up and fully circulate ( 90 deg C water temp) before exceeding 3K rpm.

Edited 1 September, 201114 yr by vwcabriolet1971

It would be interesting to know if the replacement engine was a "complete" engine ( as fitted in the factory process) or was it a new "long block" engine that required most of the old engine ancillaries to be transferred over . If it was only a new long block, then the injector & injector sealing problems could have been "induced" by the dealer during the engine re-assembly.

Why would a new ECU fuelling map update be required ? What was wrong with old one ?

I think you have enough grounds to reject the car . One way to get Skoda customer services attention is to publish your problems and Skodas reaction to them on Twitter. Most big companies have people in their customer services depts whose only job is trawl Twitter to see any adverse company comments. They don't like any bad publicity and will quickly take action to correct it.

It makes sense to allow engine ( and oil) to warm up and fully circulate ( 90 deg C water temp) before exceeding 3K rpm.

Remap?

When injector one failed Skoda refused to repair under warranty until the dealer informed Skoda the whole engine had been replaced including injectors.

Yesterday got stranded at hire company, informed I could change the Fiat 500 I had for a larger car a Hyundai I30 and the cars could be swapped at 4pm from the hire company, on arrival I was informed the swap car had not been booked and I had to wait for 30 mins while it was sorted.

Ah man that's awful. Especially as the Greenline II seems such a good car. Seems like you've been very unlucky. If it was me, I'd be pushing Skoda and looking to draw a line under the whole thing as quickly as possible. I haven't heard of these problems with other Greenline's so hopefully it's just that one car and you can get a better quality replacement. Keep us updated

What a terrible story.

I would get Skoda to try and act quickly on this and get rid of the car if possible or at least give you a 'new' 3 year warranty from the date of the last repair.

Keep us posted.