Independent specialist Baz Meredith tackles a full engine replacement on a 2017 Volkswagen Transporter T6 bi-turbo, which suffered catastrophic internal failure at just 65,000 miles.
Opting to drop the engine complete with the subframe to save time, Baz stripped the front panel, disconnected the wiring loom at the ECU, and unbolted the drive shafts, exhaust, and suspension components.
Upon dismantling the original unit, teardown revealed severely scored cylinder bores and a bent connecting rod, confirming major structural failure despite the vehicle’s low mileage.
Rebuilding onto a bare block required transferring the twin turbochargers, fitting an essential crank spigot bearing to protect the gearbox, and renewing all manifold gaskets and stretch bolts.
The job hit a major snag during setup when a new aftermarket EGR valve failed basic settings calibration, forcing Baz to fit a genuine OEM unit to clear fault codes and complete the job.
