2005 Nogaro S4 4.2 Newbi Owner (England)

JimGreen

Registered User
Yep, both of the new actuators failed to operate correctly, or in the same way that the two old actuators are operating............ Really p-ssed off how much extra work this has caused.

Really tempted just to put my old actuators into the new electric cam adjusters to get the car back up and running, but once that's done it would be another huge job to replace them at a later date with new actuators.
 

S3 GAZ

Registered User
Love reading your stuff Jim. Bit of a nightmare but at least you found the culprit and most likely down to the knowledge of your tech.

More disappointed with Audi their Quality control.
I would be having a go at them especially with two units failing to work and the amount of labour its caused.

Fingers crossed the replacements cure the faults and rough idle.
 

TomCrox41

Registered User
Sorry to hear your having problems with this build, its been a great inspiration for my own.

don't be tempted with your old actuators.
You know as well as i do its a pain getting too these parts, plus those annoying things like the single use bolts on the cam, these gaskets and seals that have to come off, risk of damaging them every time they are moved.

Have you been able to speak to Audi about the actuators yet??? you may have to be very pushy in your arguments with this sort of thing, I would imagine they will want to send them back to manufacturer to be tested and inspected before they hand out any replacements. If you kick up a fuss and remind them how much you have given them recently they should be able to get some to you quickly.
 

JimGreen

Registered User
Hi Tom

I can only guess at what Audi's decision may be, but at the end of the day they have a full workshop where they can very quickly test the new actuators against the old actuators, it's a test that takes only a minutes and they will be able to see the problem...... So I live in hope. Unfortunately with Monday being a bank holiday, the earliest we'll be able to do anything is Tuesday.... Arghhhh.
 

dualmono21

Well-Known Member
VCDS Map User
keep fighting jim its worth it in the end mate sorry things are not going your way at the moment
thanks for posting up the pics and descriptions in future it may well help someone else who has the same problem
 

JimGreen

Registered User
Thanks Guys

Hopefully we'll be back on track by the end of next week, just a pain that now we have to purchase the inlet cam Mechanical Adjuster bolts, as they're once only items and obviously a days work for my tech stripping the back of the engine again.

Hopefully this thread may help others in the future as you say.

If Audi get snotty about it and keep us waiting, then I will put the old actuators into the new Electronic Adjusters. At the end of the day, there's not a lot that wears in the Actuators, it's the electronic adjusters which have the timing chain tensioner incorporated into them that wears. The actuator is just a piston which moves one way or the other.

I'll see how we get on with Audi on Tuesday.
 

monodude

Registered User
Hi Jim,

That's a real pain! I would say you will be fine with Audi parts I had a problem with the belt tensioner when I replaced it, when I went to fit the new part I noticed the wheel was twisted and not in line with the belt! I took it straight back and they replaced it no questions. with the amount of money you have spent and time wasted finding this fault I would say that they will sort it straight away for you. Seems really odd that both have failed hopefully nothing with the wiring has shorted them out or something to damage them when they are in the car?

As a matter of interest, you have managed to remove the mechanical timing gears with the engine in situ? was this on both banks? Would be good to know as this is a question that has popped up over the years. Some people say it can be done with the engine in the car and some say you have to take the motor out.

I hope you get it sorted soon and no more issues... fingers crossed.

Cheers

Al
 

JimGreen

Registered User
Hi Al

Yes, both units removed with engine in place, it certainly is possible, but tight.

Will put some pics up soon.


Jim
 

JimGreen

Registered User
Only have a pic of the passenger side (This is a UK car, so for US cars this would be the drivers side) on my phone at the moment.





Don't have pics of the drivers side, but for UK Cars, the drivers side is the easier of the two.

Will add them soon
 

monodude

Registered User
Thanks Jim, I think that's really useful info to have especially for anyone that needs to change the mechanical adjusters as most places say engine out... so will save a lot of time and labour.

Did you manage to speak to Audi Re the parts needed? hope it all went ok.

Cheers

Al
 

JimGreen

Registered User
Yes, they're agreed to a return and re-supply of the two units.

It's only the actuator/solenoid part that's defective, but apparently they only come as a complete unit, so they're send me out two new ones.

Here's my old unit complete and along side it the actuator/solenoid removed from one of my new units.

When removing these with the engine in situ, the hardest side is our (UK) passenger side, as there's a metal coolant pipe that runs alongside the engine and bends and goes straight behind the back of the engine, which first prevents you from having enough clearance to remove the timing chain cover, however with a lot of juggling around it is possible (Hard to explain, but just keep juggling the pipe and the back cover around and eventually the back cover can be pulled clear, giving you access to both the mechanical adjusters and the electronic cam adjuster unit, which also contains the top chain tensioner as can be seen in my pics as a complete unit.

It's not a job you would want to have to repeat though.


 
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JimGreen

Registered User
New units now back on the engine and putting it all back together.

We removed both solenoids/actuators from the units and tested them.... Both appear to be working correctly, so we soaked them in engine oil, replaced them in the new units and now they're back on the engine.

In the process of putting it all back together now.

Keeping my fingers crossed.
 

Mike.M

Registered User
Sounds like good news!
 

JimGreen

Registered User
I'm hoping so Mike, will know tomorrow when it'll be finished, so much to put back.
 

monodude

Registered User
Hey Jim, fingers crossed that's the end of the problems for you. Maybe you can have it ready for the Surrey rolling road meet at Farnborough for next Saturday 6th Sept. I am sticking my car on to see what its doing.

Cheers

Al
 

JimGreen

Registered User
Hi Al

Pm me the location and I might well be there.
 

JimGreen

Registered User
;D ;D ;D Back on the road again...... Isn't there a song called that.

Well...... we finished the job this morning just before mid day, cleared all the previous codes that had caused us to half remove the engine again, took if for a drive (About ten miles) ran perfectly, really strong on torque and power.

So, I took it home, gave it a really quick wash and then went for a long drive, steady for about the first ten miles and then gave it a little more and gradually started to increase the rpm further up the range.

Suddenly when accelerating hard in third gear I felt the engine flutter and hesitate, and a loss of power. So I slowed down a little and pulled into a service station, got out my little VAGSCANNER and checked if I had any fault codes...... Sure Enough : 16405 bank 2 camshaft a (intake) p0021-002 ****** setpoint not reached (over advanced) mil.

F-ck.....Sh-t..... and a lot worse...... So I cleared the code and started on a very disappointing drive home, BUT suddenly after driving for about five minutes and deliberately driving on and off the throttle, full power returned and the responded perfectly to the throttle. So I decided not to go home but continued on my driver for another hour in all types of roads and traffic, clocking up over 50 miles...... Without any further problems.

Arrived home, checked everything physically, ran another scan, NO Fault codes at all. Went for another thirty minute drive, no problems at all.

Oh I'm hoping whatever it is has sorted it's self out.

I did wonder if the pistons in the actuator/solenoid could be a little tight, being brand new and maybe now they're bedding in.
I'm certainly hoping so.

Just going to let the car cool down so I can start it from cold and go for another run tonight.

So, for the last sixty miles she's running perfect, after that one hiccup....... Keeping my fingers crossed and it is so nice to have no timing chain rattle on cold or warm start up.

Here's a few pics of today, back on the road at long last. Haven't really given it a good clean yet, but what the hell.











I'll keep you informed...........
 

JimGreen

Registered User
:thumbs up::thumbs up: Another drive and no fault codes...... Running Great.

My fingers are crossed, My Legs are crossed, My toes are crossed...... It's damned hard to drive like this.
 

JimGreen

Registered User
Thanks Mike..... Hoping it helps others doing the same job.

If you plan on doing the job in a week........ allow three...... LOL. You'll always find that you need the odd gasket, bolt, etc and then find something that you decide is better changed now while you have the engine out etc etc etc.

One HUGE Surprise...... There are two washers, that go between the end of the inlet cam and the mechanical timing adjuster, they're "Diamond Coated"..... whatever that means...... £30 EACH ! ! ! ! Everything says you should change them so I did, but some of the prices are crazy....... £950 for the dual mass flywheel....... Arghh.

Oh, don't ask what this job cost me PLEASE, one day my girlfriend might find this tread and realise why we never had a holiday this year...........LOL.


Jim
 

JimGreen

Registered User
JHM Tune (93) Ordered :arco:
 

TomCrox41

Registered User
Well done man, Glad to see you got this sorted!

Shes looking good!

I hate those first drives after major work, everything little noise makes you nervous! i find that i get overly worried about little things, and start second guessing everything.
 

JimGreen

Registered User
I know exactly what you mean, I've done over a hundred miles without the radio on....... LOL
 

JimGreen

Registered User
I'm loving it......

Still running perfectly after a week of varied driving.

Just about to download JHM Tune (93).

Thanks for all the "Likes"........... It's been a long road, but I'm almost there.
 

Mike.M

Registered User
Well done mate :applause:
 

Nifty

Registered User
Enjoyed this thread.... I hope your nightmare is over..... And you get that holiday next year......

Tidy looking car by the way..... Takes balls to remove an S badge... :)
 

JimGreen

Registered User
I was thinking about putting a 1.9 badge on, but the registration gives it away.

Still running strong with no further issues, just waiting to Flash the ECU with the JHM Tune.

Thanks for watching the thread.


Jim
 
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JimGreen

Registered User
LOL, that's what I like about the S4, it's so "Wolf In Sheeps Clothing"

No.... Went for the Messy Burger...... LOL.

Have to catch up some time.

Regards Jim
 

JimGreen

Registered User
JHM Tune (93) downloaded onto ECU, this along with decat downpipes and full non resonated Milltek, the car is running like a dream. Big increase in mid range torque, sounds great and all with perfectly silent starts from cold and hot, it's great to have all this and no timing chain rattle, it feels like a new car with WAY more power than when standard. Three hundred miles now of pure enjoyment and no fault codes. If anyone is trying to justify doing all this work, on a car they treasure DO IT, that's all I can say, it's like driving a totally different car. I don't know what bhp and torque I have gained with the JHM Tune and exhaust modifications, but it is noticeable, no doubt at all.
 

JimGreen

Registered User
Now completed five hundred miles since completing the rebuild and it's running like a dream, no more fault codes, the issues with the sticking actuators seems to have resolved themselves, probably due to them bedding in over the last five hundred miles.

Loving it............. Few pics after a wash and polish.







Now I have the car that I wanted, modified the way I want it, in mint condition with a long lease of life ahead.
 

JimGreen

Registered User
Ha ha......... Not for a while Dan, Not for a while.
 

DanielJames

Registered User
Ha ha......... Not for a while Dan, Not for a while.

It looks a lovely motor. Nogaro blue is an awesome colour. It's one of those where if you're into Audis, you'd know what it is. Every other road user would just think, "that's a nice looking car".

Seeing the effort you've put into this car it'd be good to see what you got up to with your M3 and M5. I'm a BMW man too owning both an E36 and E46 in the past (328i Sport and 320d). The Audis feel the same, only different... would you agree? I really like mine and I can tell it's a well made car just like the BMWs were, the interiors probably a bit nicer in the Audi but hasn't worn very well at all.
 

JimGreen

Registered User
I came to the same conclusion as yourself. Both great build quality, both have their issues (E39 M5 - Vanos Issues) and S4 Timing Chain Issues, so neither are perfect but both are enthusiast cars and both a performance saloon's.

I've had the E46 M3 and as much as a great car that it is, to give you the power you have to really keep it up in the rpm range and I prefer the torque that a V8 produces.

My E46 M3 was an immaculate car when I bought it, and all I really did was spend time cleaning the underside of the car to get it as close as I could to being back to new.

The M5 was very much the same.......

Here's a few pics............















And the M3









Now that all the mechanics on the S4 are up together, I'll spend the winter bringing the underside of the car up to the same spec as the BM's.

Keeps me out of trouble on those long dark nights..... LOL
 

DanielJames

Registered User
****** hell they're immaculate... I have to say both cars look familiar. Perhaps we have crossed paths on other forums previously.

The colours are perfect on both cars. Steel grey with the Imola leather is what I wanted on my E46 M3. I was due to buy one in the summer but couldn't due to losing my job. Hoping to get one in the Spring now, although it'll be a hard choice M3 vs S4. I don't think I'll be getting an SMG though.

I hope the E39 had an interesting interior too. Silver Grey leather would suit that colour to a tee.
 

JimGreen

Registered User
****** hell they're immaculate... I have to say both cars look familiar. Perhaps we have crossed paths on other forums previously.

The colours are perfect on both cars. Steel grey with the Imola leather is what I wanted on my E46 M3. I was due to buy one in the summer but couldn't due to losing my job. Hoping to get one in the Spring now, although it'll be a hard choice M3 vs S4. I don't think I'll be getting an SMG though.

I hope the E39 had an interesting interior too. Silver Grey leather would suit that colour to a tee.

No..... M5 was solid black, but it suited it.

I try to buy cars where I can see room for improvement, but are basically straight and corrosion free, with good mechanics and don't mind spending time travelling to find the right car. I think the M5 was the seventh I looked at after travelling from Portsmouth to as far north as Middlesboro, Well worth holding out and putting in the miles to find a good one.

M3, I was just lucky and found that with just 27k miles from new and had an owner that had garaged it all it's life.

S4 was a high mileage car (89k), but again had been garaged when not in use and the owner was in his seventies........ Another lucky find.
 

staubach333

Registered User
Hey Jim, came across this thread and was wondering if you could give me some insight! I have a faulty cam adjuster solenoid on bank 1, and I have a replacement. I'm just looking to swap the solenoid, and was wondering how involved it is to do so...I know the valve cover and upper timing cover will be removed, but are there any coolant lines/hoses that need to be removed in the process? Thanks.
 
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