T6 CFCA Engine Bore Scoring from EGR Corrosion: Diagnosis and Fix

The Problem

A 2016 T6 180PS CFCA engine developed severe vertical bore scoring across all four cylinders at only 44,000 miles, attributed to EGR valve corrosion debris contaminating the engine, with cylinder 4 sustaining a deep gouge that destroyed compression entirely. The owner had already had VW diagnose hydraulic damage and quote £12,000 for a replacement engine, but the across-the-board low compression pointed to EGR contamination as the root cause rather than a single isolated failure.

Solution

1. Order a Tafmet EGR simulator with blanking plates specified for the 2.0 BiTDI CFCA 180PS engine.
   • Source from Poland if you cannot find it locally; it is listed as the only unit available for this engine.
   • Before you commit to this route, understand the consequences: blanking the EGR stops exhaust gas recirculation, which increases NOx emissions. The DVSA MOT diesel emissions test (and any roadside emissions check) can detect the resulting fault codes and failed emissions performance, leading to an MOT failure. Removing or defeating an emissions control device can also render the vehicle non-compliant for road use. Weigh this carefully and consider repairing or replacing the EGR valve as the road-legal alternative.
2. Fit the Tafmet simulator and blanking plates in place of the EGR valve using the correct tools.
3. Route and secure the device and its wiring tidily with loom tape so it is mechanically protected and does not chafe. Do not attempt to disguise or conceal the modification from an MOT tester or any official examiner — concealing a vehicle alteration is not acceptable, and any modification should be declared honestly.
4. Perform an oil change immediately after fitting, then send an oil sample to a UK oil-analysis laboratory (for example WearCheck UK or Millers Oils) to confirm whether EGR corrosion debris was already circulating before the fix.
   • In the report, look for elevated wear metals — particularly iron (Fe) from the bores and cylinder liners, aluminium from the pistons, and silicon, which indicates abrasive/dirt contamination — as well as any coolant or fuel dilution.
   • The most useful indicator is the trend across samples rather than a single reading. Investigate further (compression test, borescope) if iron or silicon rises sharply between samples or if the lab flags a result above its 'caution'/'action' threshold for your engine type.
5. Continue oil changes at no more than 8,000-mile intervals and repeat oil analysis periodically to monitor for contamination.
6. If a dealer presents the 23DV EGR software recall, note that reports of running problems after it is applied come from community forum anecdote and have not been independently verified. It is not a safety recall, so you are not legally obliged to accept it; if you decline, ask the dealer to record your refusal. Treat the forum reports as unconfirmed and make your own decision.