My new (to me!) B6 S4

[^adam^]

I noticed whilst manual bleeding on my own the old fashioned way with a tube into a bottle of new fluid, that there was a hissing sound from the fluid reservoir whilst pumping the pedal. I got my assistant (aka wifey!) to pump the pedal whilst I recorded it as I wasn't sure if this was normal. I've only really pressure bled before.

https://www.dropbox.com/home/Camera Uploads?preview=2015-11-29+22.04.59.mov

 

[^adam^]

Just as I thought I was making progress ....

After weeks of zero time spent on the S4 (worked in Vegas for a week!) I finally got some time on it today.

Got a new torque wrench for Xmas from the wife as my old one didn't go as high as 100nm as needed for some of the suspension. Got that all torqued up now.

Bought myself the Sealey vs820 brake bleeder tool. My old Gunson sounded like it was starting to leak and a lot of info online suggested I needed 28pdi (The Gunson only up to 20psi).

Started well, front left (passenger) bled quickly with 28psi, loads of air out, then new fluid. Front right did OK also. As I worked back, I needed to push up the PSI to get the fluid through, up to around 32psi but eventually got some air out and fluid through. Closed everything off, all four wheels back on and down on the ground for the first time in ages. Started up, still had ABS and ESP light on and the (!) light flashing.

Brake pedal went straight down to the floor Absolutely no pressure at all. Quick scan was showing the ABS model as incorrectly coded which is strange and steering angle sensor, so need to sort those.

On the verge of giving up and getting a mobile mechanic in or having it towed to garage. So close yet so far

 

[sumo]

Have you tryed the old trick of putting a stick on the pedal with it all the way down on the floor and leaving it over night? Sounds like you can't get fluid past the pump?

 

[^adam^]

No, today put some more fluid through front left, loads more air came out. Moved to front right, even up to mid 30s psi, very little fluid through.

Will try again on the rear tomorrow, should get more time

Think I just need to repeat bleeding until all air out.

 

[^adam^]

Again, just as I thought I was making progress.

Following a new guide here: http://blog.micksgarage.com/project-gti-how-to-bleed-your-brakes/

Running the ABS pump whilst bleeding (Output test on VCDS) with a helper pressing down on the brake pedal gently.
Front left is fine, nice clean fluid and no air bubbles, pushed about 200ml of fluid through here with no problems, can be done with as little as 15psi pressure. Front right, again, started pushing fluid through, plenty of air bubbles, they just kept coming, then nothing, no fluid, no bubbles nothing. Tried higher pressure, nothing, tried lower pressure, nothing.

Haven't tried yet on the rear brakes.

Found a local VAG specialist called VGS. Will have the car towed to them next week, they're closed until the 4th, so will keep trying until then.

 

[neil ratcliffe]

loving the car mate. sorry to read about the trouble you are having with the abs pump. hope you get it sorted soon, so you can enjoy that v8 power.

 

[^adam^]

Yeah I'll get there, got another car so not the end of the world that this one's off the road. Learning all the time, enjoy it really.

I'm sure there's a process to complete, I just don't know it/doing it wrong. All the expensive stuff should be complete now, just the labour to bleed the air out. Hoping VGS can come to me rather than tow it to them. If I do tow it to them, I'll tell them not to give it back until it has new MOT!

 

[neil ratcliffe]

i do hope you get it sorted mate.

 

[rjm180]

i do hope you get it sorted mate.

+ 1.

 

[^adam^]

Thanks!

It will get sorted one way or another! Looking forward to getting it back on the road.

Planning new discs and pads all round once the weather picks up a bit, plus switching out the Concert 2 unit, perhaps for RNSE. We'll see!

 

[neil ratcliffe]

ive swaped out the oem headunit for a dab player. got glass antenna atm, but going to upgrage the a sharks fin type very soon. mine came with new discs and pads all round, so this has save me abit of money. so left more in the kitty

 

[^adam^]

Fingers crossed! Car was just collected and heading for VGS for brake bleed, checkover and MOT.

VGS are nice and close to me, just a couple of miles. They don't seem to advertise much, would be great to find a really local VAG specialist!

 

[neil ratcliffe]

hope it all goes well mate, and she is back on the road.

 

[^adam^]

No such luck today, VGS came up against the same problem I had, no fluid through two calipers. They think there's a blockage somewhere and going to look into it. Update tomorrow lunchtime.

 

[Garth_S3]

That sucks mate. At least it indicates it wasn't something you were doing wrong. Good luck getting it sorted.

 

[neil ratcliffe]

thats not good news have you checked the condition of both the front flexi hoses, could be where you are having a problem.

 

[^adam^]

I replaced all four hoses at the same time as the ABS module was away for repair.

In hindsight I probably should've replaced the hoses whilst the ABS module was in and done in stages, bleeding in between but oh well, too late now!

 

[^adam^]

Just spoke to VGS, blocked line in master cylinder, needs a new MC.

Not too expensive fortunately, genuine part circa £130 plus two hours fitting, plus the two hours diagnostics.

Could've been worse! Aiming to collect on Tuesday with a fresh MOT. Getting excited now. Then it's time for a damn good clean.

 

[neil ratcliffe]

hi mate, was only a thought. at least they have got to the bottom of the issue. bet you are looking foward to driving her again, glad its finally sorted.

 

[^adam^]

Oh yes, desperate to get it back with MOT now!

Spending will have to go on hold on it now in terms of mods/upgrades. Nothing but service items this year, just booked to go to Vegas in August!

 

[^adam^]

Just spoke to VGS.

Failed MOT, but only on condensation in the headlights! Guessing that's from sitting around for so long without use. Brakes all sorted. Hopefully collecting tonight or tomorrow.

Excited now.

 

[^adam^]

Collected last night.

Fresh MOT sorted, brakes nice and firm.

Not all is 100% though, engine management light is on and not running too well at low speeds, and ESP light was on. Although after a couple of firm stops switching off and on again the light was gone.

Will report back with scan this evening once I've had a change to do it.

Glad to have it back and running though, even treated it to some new mats!

 

[^adam^]

Damn, wish I didn't run another scan, more error codes than ever!

Address 01: Engine Labels: 079-910-560-BBK.lbl
Part No SW: 8E0 910 560 B HW: 8E0 907 560
Component: 4.2L V8/5V 0020
Coding: 0011771
Shop #: WSC 63251 000 00000
VCID: 24404DE8E49CE01E35-515A

3 Faults Found:
17979 - Left Engine Mount Solenoid Valve (N144)
P1571 - 001 - Short to Plus
16684 - Random/Multiple Cylinder Misfire Detected
P0300 - 001 -
16692 - Cylinder 8
P0308 - 001 - Misfire Detected
Readiness: 0110 1101


Address 03: ABS Brakes Labels: 8E0-614-517.lbl
Part No: 8E0 614 517 Q
Component: ABS/ESP allrad 3033
Coding: 04597
Shop #: WSC 12345
VCID: 366487A01200628E9B-513C

2 Faults Found:
01200 - ABS Valves Supply Voltage
35-10 - - - Intermittent
01425 - Yaw Rate Sensor (G202); Signal Wire
57-10 - Electric Circuit Failure - Intermittent


Address 08: Auto HVAC Labels: 8E0-820-043.lbl
Part No: 8E0 820 043 AC
Component: A4 Klimaautomat 1323
Coding: 00000
Shop #: WSC 63251
VCID: 62CC0BF0EE08AE2E07-513C

2 Faults Found:
01272 - Positioning Motor for Central Flap (V70)
41-10 - Blocked or No Voltage - Intermittent
01232 - A/C Compressor Regulator Valve (N280)
30-10 - Open or Short to Plus - Intermittent


Address 16: Steering wheel Labels: 8E0-953-549.lbl
Part No: 8E0 953 549 N
Component: Lenksáulenmodul 0611
Coding: 01112
Shop #: WSC 00000
VCID: 3E749F803A30AACE43-4B32

1 Fault Found:
01317 - Control Module in Instrument Cluster (J285)
49-10 - No Communications - Intermittent


Address 55: Headlight Range Labels: 4Z7-907-357.lbl
Part No: 4Z7 907 357
Component: dynamische LWR D09
Coding: 00060
Shop #: WSC 63251
VCID: 04002D68145C001E55-4B4A

1 Fault Found:
01535 - Control Circuit for Right Headlight Range Adjusting Motor (V49)
30-00 - Open or Short to Plus

Address 56: Radio Labels: 8E0-035-1xx-56.lbl
Part No: 8E0 035 195 M
Component: symphony II NP2 0410
Coding: 01200
Shop #: WSC 71936
VCID: 316EB4BCFB6E45B6CE-508E

1 Fault Found:
01305 - Databus for Infotainment
49-10 - No Communications - Intermittent



So, the headlight range adjusting motor must be down to the fact it's connected to the lower arm when I changed them.

Time to start researching everything else.

 

[^adam^]

The good news is I've found the source of the misfire, the bad news is I guess the next step is getting the rocker cover off again

Took the coil pack off cylinder 8, spark plug chamber full of liquid

The other little bit of good news is that the ESP light is out, guess a bit of hard braking has reset the system.

 

[^adam^]

So, might be getting somewhere. Removed the spark plug from cylinder 8, cleaned it up, all fluid removed from chamber. Hooked all back up, cleared codes, ran engine, then scanned for codes again, still showing as misfire on cylinder 8.

Removed coil pack from cylinder 8 and switched with cylinder 5. Cleared all codes then ran engine again for a few minutes. Switched off and ran codes again, this time the misfire was listed as cylinder 5. So hopefully that's highlighted an issue with the coilpack rather than anything more sinister. Doesn't solve how the fluid made it's way into the chamber in the first place, I wonder if this has killed the cylinder pack?

I'll call the dealership on Monday to find out if they've been replaced under the improvement program, if not, they're around £30 each at ECP.


Next question RE the engine mounts.

I think that the passenger side is leaking. Hopefully you can confirm from the picture.

There's a puddle down on top of the subframe, noticed when looking down with the torch a reflection.

 

[john777w]

Engine mounts have a red fluid inside them, is this what is leaking?

 

[^adam^]

More news.

Spoke to my local Audi dealer today. All coil packs are being replaced FOC next week due to an improvement program.

Hopefully that will cure the misfire!

Next up the engine mounts and headlight auto adjustment.

I can't really tell if that puddle of fluid is red and from the engine mount, but the engine mount is throwing up a code and exhibiting faults (shudders at low speed/revs) so guess it needs doing.

 

[^adam^]

So just had call from the dealer, the coil packs have been changed FOC and the misfire is gone.

But they've said the ABS and ESP lights are on so not sure what they've done, as they haven't been on since the brakes were sorted at the MOT two weeks ago. I'll find out what codes have been thrown up when I collect later.

 

[Jimmy TDI]

I would have expected them to have scanned it to see what is showing foc seeing as they weren't there before they worked on it.
It could be something as simple as the system function test for the slip ring if they have disconnected the battery whilst fitting the coilpacks.

 

[^adam^]

He said they did but didn't have the codes to hand. I scanned when I got home and came up as low voltage to ABS sensors or something similar, I can't remember exactly.

Car drives wonderfully smooth now after the coil pack replacement, no misfire, not low revs shudder. As it should be

Also, they quoted me for the engine mount replacement, £1,110! Ha, will be either doing myself or going local on that one.

The invoice they gave me for the coil pack replacement under recall was £650ish, so the cynical side of me thinks they're trying to claw some of that back

I'll take a look at the weekend.

On the headlights:

I removed the drivers side headlight and have removed the auto height adjusting motor, will switch across to the passenger side to see if the error follows it, shouldn't take too long. If the error follows then it's a replacement motor needed, if it doesn't follow then likely the wiring or controller.

 

[john777w]

The invoice they gave me for the coil pack replacement under recall was £650ish, so the cynical side of me thinks they're trying to claw some of that back

There's nothing to claw back as Audi would have paid the labour & parts costs!! In fact it was probably a nice little job for them, once it was authorised by Audi.

 

[cobraBLACK]

The invoice they gave me for the coil pack replacement under recall was £650ish...

It takes a few minutes to replace a coilpack (and they're not expensive parts) so that sort of charge is ludicrous.

 

[^adam^]

There's nothing to claw back as Audi would have paid the labour & parts costs!! In fact it was probably a nice little job for them, once it was authorised by Audi.

Fair enough. I'll take a proper look at the weekend. Hopefully the headlight auto adjustment is a quick fix, then it's on to the engine mounts!

 

[^adam^]

So, taking a look at the headlight auto height adjustment. I kept getting a warning light on the dash for it. Code came up for right auto adjuster. I removed both the right and left and swapped them. Seems to solved the issue. Maybe something was loose inside the light itself but re-seating seems to have cured. Whether its long or short term we'll see.

One thing I can't seem to do is adjust the headlights via VCDS. I've followed the steps on the site but not available.

I've also re-seated the power to the ABS module and cleared the codes. I'll take it for a drive tomorrow and see it comes back, if it does I'll get in touch with BBA Reman to see what's up. I'd hate to have to remove it again!

I'll deal with the engine mounts at a later date now that the coil packs have cured the engine rumble at low revs. Also the A/C compressor once the weather clears up.

 

[^adam^]

So the ABS module has gone back to BBA reman as the 01200 insufficient voltage error came back intermittently. They've told me I need a reconditioned module. Fortunately they can subtract the cost of the repair that I've already paid from the cost of the refurb unit. Should get that in a couple of days.

I've also bought a replacement used headlight range control unit from eBay for £25 so hopefully that should fix the range issues. Worth a risk at that price IMO.

To treat myself, I've bought a Concert 2+ to upgrade from the Symphony 2. Updates the interior nicely I'm sure you'll agree.

Old Symphony 2

New Concert 2+

In total the upgrade cost around £150. The unit itself was £80 inc postage, the cable from Kufatec was £60 and the aux-in cable (not fitted yet) was £10. I did want an RNSE mk2 but at around £400, and it doesn't do full postcode navigation, that put me off.

 

[^adam^]

Another little win.

Swapped the headlight range control module with one I bought on eBay for £23 and the headlight error has now gone. Was very annoying having the MIL on the dash for that.

Just had the refurb ABS module turn up also so will try and fit that this afternoon!

 

[pablo]

I feel your pain I bought an 06 S3 with a bulb error light on and it drove me mad. turned out they were the wrong headlights and it was 700 quid for a used set. all to get a light off!

 

[^adam^]

Update:

So, got a refurbished ABS module from BBA Reman fitted on Saturday and all seems to be well with the ABS. Needed coding of course, so thank heavens I have VCDS. All codes and dash lights gone which is nice. They sent a whole ABS unit rather than the module, so I have a spare refurb ABS pump in the garage which is a bonus.

The headlight error is back which is annoying so will take a further look into that over Easter but I'm guessing it's the height sensor on the front left lower arm.

Getting there.

Oh, and the car is booked in to Audi in Coulsdon for auto transmission gearbox oil and filter change on Saturday at £175. I've seen on another thread that it should be more, so lets see if they actually follow through.

Treated myself to some new cleaning bits so will spend some time over Easter giving a nice cleanup. Might start looking into getting the front bumper resprayed and also a couple of little marks patched up.

Any recommendations around Croydon area?

 

[^adam^]

Too good to be true.

Coulsdon Audi just phoned, tiptronic gearbox oil isn't changed, offer of £175 is only for multi tronic.

 

[Jimmy TDI]

At the end of the day they have to do it for the price they gave you, or its false advertising.

At least you have the brake issue sorted now though, as that's been holding you bak for a while now.