There is only one way to effectively and completely eliminate excessive engine oil consumption in TSI/TFSI engines.
It is necessary to perform a major engine overhaul with the replacement of defective pistons with third-generation pistons, which are exclusively manufactured by Kolbenschmidt.
This German manufacturer produces pistons for most European cars, including Volkswagen, Audi, Seat, and Skoda.
During such an overhaul, it is also essential to repair worn cylinder liners, replace crankshaft bearings, and regenerate the cylinder head, as well as install new all timing drive components, and all seals and gaskets that must be removed during repair.
Any other repair methods do not guarantee that the problem will not return very quickly.
If you are considering repairing your car with an oil problem, read our article to the end.
Before you choose a contractor for such a serious repair, ask what warranty you will receive, read reviews from customers who have used the service in the selected workshop and have driven at least 50,000 km. It is also worth finding out what parts the workshop uses, what equipment it has, and its experience.
An engine overhaul is like open-heart surgery; it is well performed by only a few cardiologists in specialized clinics, not by general practitioners.
Just as even the best doctor cannot perform surgery without the proper facilities, even a very good mechanic cannot properly perform an engine overhaul without the right machines and equipment. So let's hope it doesn't end up like the famous saying, "the operation was successful but the patient did not survive."
Due to the high demand for such services in Poland, many companies have emerged that try to repair the oil issue in TSI/TFSI engines. To attract customers, unknown workshops often offer repairs much cheaper than the cost of the parts they supposedly replace. Not to mention that in most of these workshops, you won’t receive an invoice or a warranty for the engine overhaul; they certainly won’t replace all the parts necessary during an engine overhaul (unless they are offering the service for free and even then, they are likely paying a lot extra for the parts installed).
Mechanics offering cheap TSI repairs often do not replace the pistons at all but instead modify the old ones. Such modification involves re-machining the grooves in the worn piston for wider rings, which supposedly solves the problem of oil scraping from the cylinder. If successful (the piston doesn’t crack during machining and the groove isn’t cut too large), this may partially solve the problem temporarily. Partially because right after such a repair, engines consume between 0.2 and 0.5 liters of oil per thousand kilometers (which is within the norms allowed by the manufacturer, so the repair cannot be deemed improper). Temporarily because after driving 20 to 50 thousand km, the problem returns as the rings become stuck. Often, cracks also occur in pistons weakened by the machining. Then, another engine overhaul is necessary. We have already repaired many engines after such cheap “overhauls”.
Some workshops replace pistons using cheap substitutes that have been available in automotive wholesalers for several years. This solution is better than machining worn pistons, but unfortunately, it also does not completely and permanently remove the problem. None of the cheap substitutes are third-generation pistons with improved design. Moreover, most mechanics install new or re-machined pistons into blocks with worn cylinders, which is a fundamental mistake. Such a repair cannot be called an engine overhaul.
We remove the engine from the car and then strip it of all its auxiliary components. The engine itself (block with the head and oil pan) is disassembled into basic parts.
We remove all gaskets, seals, bearings, and pistons. We never reuse these components for reinstallation in the repaired engine. We always use new ones.
All remaining parts are initially washed and then sent to an ultrasonic cleaner, where they are thoroughly and precisely cleaned of all contaminants using cavitation technology with ultrasonic waves. This modern cleaning method ensures perfect cleaning of all engine components, even in the most inaccessible places, such as oil, intake, and exhaust channels, without causing any damage or scratches.
After such cleaning, a detailed inspection, precise measurement, and evaluation of wear and condition are performed, and a verification of components suitable for reuse is conducted. The engine block and head are checked for the tightness of oil and water channels. If leaks are found due to cracks, the head or block is only suitable for replacement. In TSI engines, this situation is very rare and occurs only in cases of external mechanical damage (accidental) or damage caused by unsuccessful repair attempts.
and once again ultrasonically cleaned. The crankshaft is measured and checked for wear and is computer-tested and balanced, then honed. If it fails the tests, it is replaced. The engine head is planed, the valve seats are milled, valves are ground or replaced, and new guides and valve seals are installed. After the entire process, the tightness of the intake and exhaust channels is checked. During engine assembly, we use only original parts from companies that produce for the VAG group. We do not skimp on details. We replace all wearing parts, and those that should be replaced according to the manufacturer's service instructions. All repair activities are performed in accordance with instructions, using the appropriate tools and specialized equipment recommended by the manufacturer.
In all TSI and TFSI engines, we replace pistons with rings, using new third-generation pistons. We replace all bolts, gaskets, and plugs that the car designer recommends replacing during an engine overhaul.
