Exhaust valve failure???

Mark Brunskill

Mark Brunskill

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Be gentle - new to these parts :sign imnew:

I set off to work this morning and thought the car was louder than normal. Cutting to the chase, I cycled through the drive select and there was no notable change in exhaust note. Having got down on my hands and knees it turns out that one of the valves is stuck open. Just wondering if this is a common problem and potentially an easy fix?
I’m booked in at the dealer on the 16th but if you guys have the answer then i’m all for that.
I’m concerned that the valve inside has failed and it’s not the bit on top of the exhaust and the dealer bums me for it as I would guess an exhaust related problem won’t be covered under warranty.
Thanks in advance :bye:
 
Can't see how the dealer can charge you for this, unless its damaged, given the age of the vehicle :)
 
You'll be covered on this. Nothing should be failing on a car that new.
 
Definitely have to cover this on warranty I agree.
BTW, go easy on your titles - I choked on my afternoon cuppa thinking you might have dropped an engine valve..:sadlike::sadlike:
 
Noted - maybe the title should be “My neighbour offending device is stuck in most offending mode”
Thanks for the replies so far.
While I’m on, the brakes squeal little like hell at low speed. A few good stops sorts it but as I only commute across town that is unachievable - is it just one of those quirks I have to live with? Come to think of it, what’s the going rate for a new set of front disks and pads as they look pricey. I’ve had a look about on the web but can’t find a price for oem items and those which are not oem are towards four figures :D
 
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HaHa! Like it!
You must mention the brakes at the same time as the exhaust - this is another long running complaint that they have to do under warranty. Certainly press them all the way before thinking of replacements as they are now past four figures! Can you reach behind the front wheels and feel the back of the calipers? There should be some resonators which are like small tin cans screwed into the caliper - if these are not present then this is an Audi fix that goes a long way in stopping the noise. If your dealer is any good, they should whip out the pads and smear some brake squeel paste on the edges where they slide on the caliper...
 
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audi upgrades
That will work - make sure that you wrap the plugs and bung the sockets up well as there is a lot of crud sprayed up there.

One thing I really like about the RS3 is that it can be two cars in one - noisy in dynamic and quiet in comfort. There are times this is useful. I have just come back from a week in Spain driving through some of their national parks where the roads, like all their roads, are super smooth and bereft of traffic. It was in the high twenties and an absolute joy in comfort mode driving to the speed limit taking in all the scenery with no pops or crackles..!
 
I’m surprised it can’t be done via VCDS as my previous 2 S3s were done
 
My cars months away but I’ll be keen on knowing what the best/easiest way of ‘deleting’ the valve is
 
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I am sure the flaps work the same as the PFL, then the 'easiest', not so sure it being the best, is to pull out the electronic plugs.
 
Hal Adams said:
I am sure the flaps work the same as the PFL, then the 'easiest', not so sure it being the best, is to pull out the electronic plugs.
Click to expand...

Coming from a 2016 Focus RS, that has an exhaust valve... I unplugged that and used an electronic ‘valve delete’ plug to stop any errors coming up... I wonder if the same plugs are available for the RS3? Or if any errors come up anyway?
 
Phil3 said:
Coming from a 2016 Focus RS, that has an exhaust valve... I unplugged that and used an electronic ‘valve delete’ plug to stop any errors coming up... I wonder if the same plugs are available for the RS3? Or if any errors come up anyway?
Click to expand...

Yes you will get errors and you can get plugs for them. Awesome GTI sell the plugs I believe, but expensive for what they are as it’s just a short as far as I know, to stop open circuit.

I don’t think Audi would bat an eyelid if the saw a valve unplugged error code stored, so I wouldn’t worry about it and save £100+.

If you do want to spend money get the AWE Switchpatch for £200 and control them with the remote. From my experience, you need the valves plugged in with the FL RS3 at motorway speeds, boomy.
 
Mark Brunskill said:
Be gentle - new to these parts :sign imnew:

I set off to work this morning and thought the car was louder than normal. Cutting to the chase, I cycled through the drive select and there was no notable change in exhaust note. Having got down on my hands and knees it turns out that one of the valves is stuck open. Just wondering if this is a common problem and potentially an easy fix?
I’m booked in at the dealer on the 16th but if you guys have the answer then i’m all for that.
I’m concerned that the valve inside has failed and it’s not the bit on top of the exhaust and the dealer bums me for it as I would guess an exhaust related problem won’t be covered under warranty.
Thanks in advance :bye:
Click to expand...

They don’t always switch the instant you switch the drive select mode, my S3 doesn’t 75% of the time. You have to actually drive off for them to operate, don’t be alarmed if you can’t hear a difference occasionally but if you don’t hear it change ever then there is an issue, may be a fuse for both to go?
 
AudiNutta said:
Yes you will get errors and you can get plugs for them. Awesome GTI sell the plugs I believe, but expensive for what they are as it’s just a short as far as I know, to stop open circuit.

I don’t think Audi would bat an eyelid if the saw a valve unplugged error code stored, so I wouldn’t worry about it and save £100+.

If you do want to spend money get the AWE Switchpatch for £200 and control them with the remote. From my experience, you need the valves plugged in with the FL RS3 at motorway speeds, boomy.
Click to expand...

£100+ wow... they were £15 for the focus haha! The switchpatch might be something to look into... I’ve got plenty of time to decide before the cars here



edit... something like this I was thinking;

https://vwpartsinternational.com/sh...oval-fault-code-off-wire-connector-new-parts/
 
So why can you open the valves permanently on my fl S3 but not on fl RS3 via VCDS
 
Phil3 said:
£100+ wow... they were £15 for the focus haha! The switchpatch might be something to look into... I’ve got plenty of time to decide before the cars here



edit... something like this I was thinking;

https://vwpartsinternational.com/sh...oval-fault-code-off-wire-connector-new-parts/
Click to expand...

They are cheaper than what I’ve seen before!

I’d still recommend trialing the car with the valves off before you buy the fault bypass, as it is very boomy at 70mph even with the standard exhaust.
 
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AudiNutta said:
They don’t always switch the instant you switch the drive select mode, my S3 doesn’t 75% of the time. You have to actually drive off for them to operate, don’t be alarmed if you can’t hear a difference occasionally but if you don’t hear it change ever then there is an issue, may be a fuse for both to go?
Click to expand...
They always switch instantly with the drive select. As I said, one works and the other is dead :(
 
Hal Adams said:
HaHa! Like it!
You must mention the brakes at the same time as the exhaust - this is another long running complaint that they have to do under warranty. Certainly press them all the way before thinking of replacements as they are now past four figures! Can you reach behind the front wheels and feel the back of the calipers? There should be some resonators which are like small tin cans screwed into the caliper - if these are not present then this is an Audi fix that goes a long way in stopping the noise. If your dealer is any good, they should whip out the pads and smear some brake squeel paste on the edges where they slide on the caliper...
Click to expand...
Are these the tin cans?
651E9E4C 5F24 4551 9F09 B9950D1309EE
 
Mark Brunskill said:
They always switch instantly with the drive select. As I said, one works and the other is dead :(
Click to expand...

Hm Strange, must be a fault with the one.. sorry I missed that, thought it was both.

You can try and wiggle the plug into the valve, but otherwise hand it over to Audi.
 
Well the valve physically still works as it operated as normal yesterday and then got stuck closed :D
 
So it turns out that the valve had indeed seized. My brand new back box is due to be fitted foc next week. They haven’t done anything about the squealing brakes but then again they haven’t squealed for over a week.
 
Mark Brunskill said:
So it turns out that the valve had indeed seized. My brand new back box is due to be fitted foc next week. They haven’t done anything about the squealing brakes but then again they haven’t squealed for over a week.
Click to expand...

New backbox!! What a design flaw by Audi, haha. Glad to hear it’s being sorted :D

Try and get the old one back, it will only go in the scrap. It will be worth a good few bob if it’s the sports exhaust, it could be repaired or valves removed.
 
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Just found this thread after I'd created one. Anyway, mine is doing the same, except it seems to be stuck open!

Can't believe it's an entire new back box...surely not?
 
D0C said:
Just found this thread after I'd created one. Anyway, mine is doing the same, except it seems to be stuck open!

Can't believe it's an entire new back box...surely not?
Click to expand...

Yes @Doc because the whole assembly is manufactured this way.

So Audi replace the whole assembly from the cat pipes joint back.....

I had a rattle on my 8P RS3 back box and they replaced the lot, even with the decats fitted
 
Would you believe it............... the valve failure seems to have happened again on the new (19 month old) exhaust. It looks like another trip to the dealer.
My warranty is up next month. I wasn’t going to extend it but £1ks worth of exhaust failing twice in less than two years has me concerned.
Does anyone have any idea how much it is to extend?
 
Just got the answer on the Audi website - £391 per year for all component cover based on up to 15k miles and a £250 excess. Sounds good to me
 
Mark Brunskill said:
Would you believe it............... the valve failure seems to have happened again on the new (19 month old) exhaust. It looks like another trip to the dealer.
My warranty is up next month. I wasn’t going to extend it but £1ks worth of exhaust failing twice in less than two years has me concerned.
Does anyone have any idea how much it is to extend?
Click to expand...

Again? Wow that’s surprising! I don’t suppose you park your car on the end of a slipway allowing the salt water to corrode the valve mechanism? Haha! That or bad luck. If you report an issue while in warranty, they will fix it after it expires also.

Mark Brunskill said:
Just got the answer on the Audi website - £391 per year for all component cover based on up to 15k miles and a £250 excess. Sounds good to me
Click to expand...

That’s a total bargain, I went for the 5-year from factory option but will most likely extend it beyond that... unless I win the lottery and start to tune, haha.

Very good price comparing my granddads which is £348 a year, with £0 excess and that’s for a 1.4TFSI.

Also worth considering, the Audi Roadside Assistance £99 a year.. cheaper than any reputable breakdown company and you get the VAG patrol support, then a hire car delivered to your door no quibbles.
 
AN, I didn't think you can extend the Audi warranty past 5 years....?
 
teslaboy said:
AN, I didn't think you can extend the Audi warranty past 5 years....?
Click to expand...

You can extend it as long as you like, if it’s one after another you get a good price as above. If you miss a year, it is sometimes double the rate above! Up until about a 12 month ago we had a ‘10 plate A4 on the extended warranty, £400 or so a time.
 
AudiNutta said:
You can extend it as long as you like, if it’s one after another you get a good price as above. If you miss a year, it is sometimes double the rate above! Up until about a 12 month ago we had a ‘10 plate A4 on the extended warranty, £400 or so a time.
Click to expand...

Cheers AN, good info.
 
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I’m booked in for my first mot next Friday and they’re gonna take a look. Typically it’s now working perfectly.
Out of interest, does anyone else find their exhaust is much louder from the left pipe when the valves are open? I thought this with the previous exhaust as well. I’m gonna get down on my hands and knees tomorrow and get the Wife to cycle the drive select to check that valve works. The valve that was playing up the other day was the left side.
 
Mark Brunskill said:
I’m booked in for my first mot next Friday and they’re gonna take a look. Typically it’s now working perfectly.
Out of interest, does anyone else find their exhaust is much louder from the left pipe when the valves are open? I thought this with the previous exhaust as well. I’m gonna get down on my hands and knees tomorrow and get the Wife to cycle the drive select to check that valve works. The valve that was playing up the other day was the left side.
Click to expand...

It could be water ingress in the plugs/sockets, I had this before when I had a plug in valve controller one morning it was switching with a mind of it’s own but it dried out of its own accord.

Audi need to unplug and try to clean with some electrical cleaner, check for any corrosion on the pins if it is an intermittent fault... or just the usual flaps themselves getting stuck.

Yes it’s normal for the left pipe to give off a little more sound, a lot of us have picked up on it.
 
Mot passed :icon thumright:
They haven’t found anything wrong with the valve so they asked me if they can hold onto the car till Monday. The loaner is a 19 plate Q7 so don’t mind if I do :rockwoot:
 
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Mark Brunskill said:
Mot passed :icon thumright:
They haven’t found anything wrong with the valve so they asked me if they can hold onto the car till Monday. The loaner is a 19 plate Q7 so don’t mind if I do :rockwoot:
Click to expand...

I was able to drive one of those earlier this year, with the 286PS engine.. what an incredible machine! Lovely thing to drive, one of my favourites to date.
 
Ahhh, mine was just a lowly 231ps.
Further investigation revealed no issues with the exhaust so fingers crossed it was just a one off blip.
 
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