B6 A4 1.8t quattro rebuilt head multiple misfires cyl#2 and #3

   #1  

drihos

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a4 b6 1.8t quattro
AWM head, port/polished, machine shop seats and valves, decked and dipped.
new oem head gasket,
new INA valve seals,
2 new intake valves,
all new INA lifters
short radius smoothed intake ports, casting line removed
new k03 borg
8k miles on 034 high flow cat with o2 spacer, decent shape, considering how much coolant got burned through it, 99% clear.
new oem oil pick up tube
stock cams, new seals(spring type).
stock injectors(old, cleaned/replaced orings previously)
replaced cracked injector cup
original n75
1 n249 replaced previously(OEM), second n249 also oem and probably original.
stock TIP, checked for slippage, did not smoke test
stock manifolds, exhaust casting flange smoothed
ngk br6e spark plugs
generic coils
new pierburg chain tensioner
new bosch cam position sensor (not from dealer)
oem kombi valve replaced previously
0W-40 mobil-1 motor oil
generic vacuum check valves and oem sjp
stock air pump
new used battery from battery warehouse, fresh juice.

OBDII scan showed random multiple misfires and cyl-2 and 3 misfire. AUtoscan showed even more fascinating codes- grrr.

Was already strongly recommended to start with comp test/leakdown, and to go with dealer parts for injectors/coils
Compression and leakdown tests pending, will follow recommendations for dealer coils etc.







Code:
Friday,20,March,2020,11:35:45:09481
VCDS -- Windows Based VAG/VAS Emulator Running on Windows 10 x64
VCDS Version: 19.6.2.2 (x64)  HEX-NET CB: 0.4508.4
Data version: 20200210 DS308.0
www.Ross-Tech.com


VIN: WAULC68E04A259267   License Plate: 


Chassis Type: 8E (8E - Audi A4/S4/RS4 B6/B7 (2001 > 2008))
Scan: 01 02 03 08 09 0F 11 15 16 17 18 25 36 37 45 46 55 56 57 65
          67 69 75 76 77
 
VIN: WAULC68E04A259267   Mileage: 259450km-161214miles
-------------------------------------------------------------------------------
Address 01: Engine        Labels: 06B-909-518-AMB.lbl
   Part No SW: 8E0 909 518 AK    HW: 8E0 909 018 A
   Component: 1.8L R4/5VT     G   0004  
   Coding: 0016751
   Shop #: WSC 63351 000 00000
   VCID: 79BA226531FC5B87E2-5160

12 Faults Found:
16683 - Boost Pressure Regulation 
            P0299 - 002 - Control Range Not Reached - Intermittent
16684 - Random/Multiple Cylinder Misfire Detected 
            P0300 - 001 -  - MIL ON
16686 - Cylinder 2 
            P0302 - 008 - Misfire Detected - Intermittent
16795 - Secondary Air Injection System 
            P0411 - 002 - Incorrect Flow Detected - Intermittent
16514 - Oxygen (Lambda) Sensor B1 S1 
            P0130 - 008 - Malfunction in Circuit - Intermittent
17511 - Oxygen (Lambda) Sensor Heating; B1 S1 
            P1103 - 008 - Performance too Low - Intermittent
16519 - Oxygen (Lambda) Sensor B1 S1; Heating Circuit 
            P0135 - 008 - Malfunction - Intermittent
16396 - Bank 1: Camshaft A (Intake) 
            P0012 - 001 - Advance Setpoint not Reached (Over-Retarded) - Intermittent
18010 - Power Supply Terminal 30 
            P1602 - 002 - Voltage too Low - Intermittent
17522 - Oxygen (Lambda) Sensor; B1 S2 
            P1114 - 008 - Internal Resistance too High - Intermittent
16524 - Oxygen (Lambda) Sensor B1 S2 
            P0140 - 004 - No Activity - Intermittent
16687 - Cylinder 3 
            P0303 - 001 - Misfire Detected - MIL ON
Readiness: 0000 0000

-------------------------------------------------------------------------------
Address 02: Auto Trans        Labels: 01V-927-156.lbl
   Part No: 8E0 927 156 S
   Component: AG5 01V 1.8l5VT USA 1212  
   Coding: 0001002
   Shop #: WSC 63351 000 00000
   VCID: 3E30F1796852BCBF97-5160

No fault code found.

-------------------------------------------------------------------------------
Address 03: ABS Brakes        Labels: 8E0-614-517.lbl
   Part No: 8E0 614 517 A
   Component: ABS/ESP allrad      4529  
   Coding: 04277
   Shop #: WSC 06435  
   VCID: 26003919C0C2047FFF-51A8

1 Fault Found:
01826 - Sensor for Steering Angle (G85); Supply Voltage Terminal 30 
            35-10 - - - Intermittent

-------------------------------------------------------------------------------
Address 08: Auto HVAC        Labels: 8E0-820-043.lbl
   Part No: 8E0 820 043 AD
   Component:   A4 Klimaautomat   1323  
   Coding: 00000
   Shop #: WSC 63351  
   VCID: 6386600DF370B157D8-5160

2 Faults Found:
00716 - Air recirculation Flap Positioning Motor (V113) 
            41-10 - Blocked or No Voltage - Intermittent
00819 - High Pressure Sensor (G65) 
            07-10 - Signal too Low - Intermittent

-------------------------------------------------------------------------------
Address 09: Cent. Elect.        Labels: 8E0-907-279-8E2.lbl
   Part No: 8E0 907 279 F
   Component: int. Lastmodul  USA 0517  
   Coding: 00003
   Shop #: WSC 63351  
   VCID: 3522EE550D647FE746-4B00

No fault code found.

-------------------------------------------------------------------------------
Address 15: Airbags        Labels: 8E0-959-655-84.lbl
   Part No: 8E0 959 655 K
   Component: Airbag 8.4EP        1001  
   Coding: 0010607
   Shop #: WSC 63351 000 00000
   VCID: 3FCE8C7D6F58B5B79C-5184

No fault code found.

-------------------------------------------------------------------------------
Address 16: Steering wheel        Labels: 8E0-953-549.lbl
   Part No: 8E0 953 549 N
   Component: Lenksáulenmodul     0611  
   Coding: 01141
   Shop #: WSC 63351  
   VCID: 3E30F1793852BCBF97-4B00

No fault code found.

-------------------------------------------------------------------------------
Address 17: Instruments        Labels: 8E0-920-9xx-8E2.lbl
   Part No: 8E0 920 950 P
   Component: KOMBI+WEGFAHRS. RB4 D42  
   Coding: 01231
   Shop #: WSC 09401  
   VCID: 3620E959106274FF4F-5160
   WAULC68E04A259267     AUZ6Z0D0086844

1 Fault Found:
00562 - Sensor for Oil Level/Temperature (G266) 
            30-00 - Open or Short to Plus

-------------------------------------------------------------------------------
Address 46: Central Conv.        Labels:. 8E0-959-433-MAX.clb
   Part No: 8E0 959 433 BB
   Component: Komfortgerát T7B    1512  
   Coding: 11788
   Shop #: WSC 63351  
   VCID: 72A815493C8A28DFA3-4B00

   Subsystem 1 - Part No: 8E1959801
   Component: Tõrsteuer.FS BRM 0204  

   Subsystem 2 - Part No: 8E1959802E
   Component: Tõrsteuer.BF BRM 0204  

   Subsystem 3 - Part No: 8E0959801A
   Component: Tõrsteuer.HL BRM 0204  

   Subsystem 4 - Part No: 8E0959802A
   Component: Tõrsteuer.HR BRM 0204  

8 Faults Found:
01134 - Alarm Horn (H12) 
            49-10 - No Communications - Intermittent
01368 - Alarm triggered by Luggage Compartment Switch 
            35-00 - -
01369 - Alarm triggered by Hood Switch 
            35-00 - -
01374 - Alarm triggered by Terminal 15 
            35-00 - -
01371 - Alarm triggered by Door Contact Switch; Driver's Side 
            35-00 - -
01035 - Electric Window Thermal Protection Active; Passenger 
            35-10 - - - Intermittent
00936 - Electric Window Switch in Front Passenger Door (E107). 
            27-10 - Implausible Signal - Intermittent
01562 - Rear right door 
            59-10 - Can't Unlock - Intermittent

-------------------------------------------------------------------------------
Address 56: Radio        Labels: 8E0-035-1xx-56.lbl
   Part No: 8E0 035 195 H
   Component: symphony II NP2    0410   
   Coding: 01000
   Shop #: WSC 74752  
   VCID: 2C14CB31DD2E3E2F29-5066

1 Fault Found:
00878 - Connection to Speaker Front Left 
            36-00 - Open Circuit

End----------(Elapsed Time: 05:46, VBatt start/end: 12.6V/12.6V)-----------



Previous AMB head cracked between intake and exhaust valves, both webs. Spark plug for cyl 2 on AMB head was found to slip through the threads after head was pulled. Burnt lots of coolant, nice crusty white flake all over #2 and #3 exhaust runners. Car sat for 3 years. Cylinders had no visible scoring or roughness to the touch while the head was off, only slight discoloration on cyl-2 single; dark, vertical band, exhaust side- centered, approx. 3mm wide. Replaced with second-hand AWM head (ported/polished), stock cams, new OEM cam chain, new pierburg tensioner, new Rein valve seals, new INA lifters, Dropped oil pan, cleaned sludge with scrub brush/diesel spray, changed oil pickup tube. Pulled oil filter adapter/cooler, cleaned thoroughly, new OEM gasket to block, new OEM o-ring at oil cooler. Cleaned oil supply and return lines to turbo. Installed new/reman denso starter.

Drove 2 blocks to emmission station after rebuild, aced it. Drove 20 miles to get permanent tags the day before- no joy, dmv closed early, but no fear. Drove 10 miles today to get them tags, misfire sputters and MIL flashed briefly enroute. 10 mile return trip, multiple misfires and MIL flashing continuously. Back roads home. At first, suspected turbo inlet hose had come loose, but no. Possibly the N75 is crusted, had to clear a glob of sludge previously from the turbo nipple hose-end during re-assembly. Auto scan showed intake cam over retarded, I had previously cleaned out cam position sensor clip to the sending unit during assembly with QED cleaner as there had been oil inside the clip boot, cam has new bosch hall sender( not from dealer).



All this is really pending leak-down test, and "spark plug/coil,3-card monte", but I couldn't wait to pop my cherry...
 
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drihos

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what are the chances its just coils and/or fried injector harness wires? It was a swift kick in the nuts to get a misfire after so much attention to detail. Any code-talkers picking up a known fix from the multitude of engine fault codes?
 
   #3  

Jef

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Going to hold judgement on anything until we know compression numbers and the results of coil/plug juggling.

A lot of "Intermittent" codes, do they come back if cleared out? Note the one in the ABS may require a short road trip to sort out.
 
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Jack@European_Parts

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Cam belt timing incorrect, chain jump or you negated a keyway damaged and floated at cam cog or crank cog?

OP could you clear all faults and post a fresh auto-scan afterward and before and right after running at idle for 30 second's but not before verifying mechanical components interference?

Did you isolate OXS heater circuits yet for apparent short?

Clearly running defeat devices electronically and mechanical spacer mechanism.

Is G40 correct reluctor space for window?
 
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   #5  

drihos

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Just got back from getting coils from the dealer. Got a compression tester too. Cleared codes, and shuffled the old coils. Def still a misfire, but no specific cylinder logged on mil at idle. About to take it out for short slow run to see if it picks up or follows which coils, then peel back injector harness sleeve and see if anything pops. Then compression test.
 
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Jack@European_Parts

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Just got back from getting coils from the dealer. Got a compression tester too. Cleared codes, and shuffled the old coils. Def still a misfire, but no specific cylinder logged on mil at idle. About to take it out for short slow run to see if it picks up or follows which coils, then peel back injector harness sleeve and see if anything pops. Then compression test.
Hey kiddo, don't you know a compression test should be done first & before taking out for a drive and observation of plugs bun rate + injectors sprayed into glass jars to check atomization pattern/volume rate?
 
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drihos

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I hand spun the crank 720deg to check the cam belt/chain marks during install, no impingement, marks lined up clean. Had marked my 16 link roller spacing with white-out and triple checked my count. Keyways on exhaust gear and intake reluctor were good. Will clear codes and check fresh scan after short hop. I'll have to search for O2 heater circuit specifics before I tango with that, but I did see that on the auto scan.
 
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drihos

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no i had not
 
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drihos

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but i was told the engine should be warm for a comp test
 
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Jack@European_Parts

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but i was told the engine should be warm for a comp test

Nope!

I hand spun the crank 720deg to check the cam belt/chain marks during install, no impingement, marks lined up clean. Had marked my 16 link roller spacing with white-out and triple checked my count. Keyways on exhaust gear and intake reluctor were good. Will clear codes and check fresh scan after short hop. I'll have to search for O2 heater circuit specifics before I tango with that, but I did see that on the auto scan.

What part number reluctor?

What about unplugging them to watch heater status & resistance DTC change and go 50/50?

Did you unplug MAF too to adapt around it and see if it smoothed out misfire to bifurcate the trims in MAP baseline?

Been here?

https://forums.ross-tech.com/showth...hain-with-adjuster-before-installing-a-bellt!
 
   #11  

drihos

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dang it, lemme do some homework now.:)

good news is I tracked it to #3 coil. Had misfires on #2 and #3, switched coils outward, logged misfires on #3 and #4. Pulled sparkplugs on #2 and #3, cleaned and swapped. Logged misfire on #4 only (originally at #3 position). Swapped coil to #1, logged misfire at #1. Replaced coil with new from dealer, no misfires. Replaced all coils, drove the piss out of it, no misfires, no codes on OBD. Autoscan still shows some codes.

Code:
Friday,20,March,2020,19:50:54:09481
VCDS -- Windows Based VAG/VAS Emulator Running on Windows 10 x64
VCDS Version: 19.6.2.2 (x64)  HEX-NET CB: 0.4508.4
Data version: 20200210 DS308.0
www.Ross-Tech.com


VIN: WAULC68E04A259267   License Plate: 


Chassis Type: 8E (8E - Audi A4/S4/RS4 B6/B7 (2001 > 2008))
Scan: 01 02 03 08 09 0F 11 15 16 17 18 25 36 37 45 46 55 56 57 65
          67 69 75 76 77
 
VIN: WAULC68E04A259267   Mileage: 259460km-161220miles
-------------------------------------------------------------------------------
Address 01: Engine        Labels: 06B-909-518-AMB.lbl
   Part No SW: 8E0 909 518 AK    HW: 8E0 909 018 A
   Component: 1.8L R4/5VT     G   0004  
   Coding: 0016751
   Shop #: WSC 63351 000 00000
   VCID: F9BAA265B1FCDB8762-5160

1 Fault Found:
16524 - Oxygen (Lambda) Sensor B1 S2 
            P0140 - 004 - No Activity - Intermittent
Readiness: 0000 1101

-------------------------------------------------------------------------------
Address 02: Auto Trans        Labels: 01V-927-156.lbl
   Part No: 8E0 927 156 S
   Component: AG5 01V 1.8l5VT USA 1212  
   Coding: 0001002
   Shop #: WSC 63351 000 00000
   VCID: BE307179E8523CBF17-5160

No fault code found.

-------------------------------------------------------------------------------
Address 03: ABS Brakes        Labels: 8E0-614-517.lbl
   Part No: 8E0 614 517 A
   Component: ABS/ESP allrad      4529  
   Coding: 04277
   Shop #: WSC 06435  
   VCID: A600B91940C2847F7F-51A8

1 Fault Found:
01826 - Sensor for Steering Angle (G85); Supply Voltage Terminal 30 
            35-10 - - - Intermittent

-------------------------------------------------------------------------------
Address 08: Auto HVAC        Labels: 8E0-820-043.lbl
   Part No: 8E0 820 043 AD
   Component:   A4 Klimaautomat   1323  
   Coding: 00000
   Shop #: WSC 63351  
   VCID: E386E00D7370315758-5160

2 Faults Found:
00716 - Air recirculation Flap Positioning Motor (V113) 
            41-10 - Blocked or No Voltage - Intermittent
00819 - High Pressure Sensor (G65) 
            07-10 - Signal too Low - Intermittent

-------------------------------------------------------------------------------
Address 09: Cent. Elect.        Labels: 8E0-907-279-8E2.lbl
   Part No: 8E0 907 279 F
   VCID: B5226E558D64FFE7C6-4B00

No fault code found.

-------------------------------------------------------------------------------
Address 15: Airbags        Labels: 8E0-959-655-84.lbl
   Part No: 8E0 959 655 K
   Component: Airbag 8.4EP        1001  
   Coding: 0010607
   Shop #: WSC 63351 000 00000
   VCID: BFCE0C7DEF5835B71C-5184

No fault code found.

-------------------------------------------------------------------------------
Address 16: Steering wheel        Labels: 8E0-953-549.lbl
   Part No: 8E0 953 549 N
   Component: Lenksáulenmodul     0611  
   Coding: 01141
   Shop #: WSC 63351  
   VCID: BE307179B8523CBF17-4B00

No fault code found.

-------------------------------------------------------------------------------
Address 17: Instruments        Labels: 8E0-920-9xx-8E2.lbl
   Part No: 8E0 920 950 P
   Component: KOMBI+WEGFAHRS. RB4 D42  
   Coding: 01231
   Shop #: WSC 09401  
   VCID: B62069599062F4FFCF-5160
   WAULC68E04A259267     AUZ6Z0D0086844

1 Fault Found:
00562 - Sensor for Oil Level/Temperature (G266) 
            30-00 - Open or Short to Plus

-------------------------------------------------------------------------------
Address 46: Central Conv.        Labels:. 8E0-959-433-MAX.clb
   Part No: 8E0 959 433 BB
   Component: Komfortgerát T7B    1512  
   Coding: 11788
   Shop #: WSC 63351  
   VCID: F2A89549BC8AA8DF23-4B00

   Subsystem 1 - Part No: 8E1959801
   Component: Tõrsteuer.FS BRM 0204  

   Subsystem 2 - Part No: 8E1959802E
   Component: Tõrsteuer.BF BRM 0204  

   Subsystem 3 - Part No: 8E0959801A
   Component: Tõrsteuer.HL BRM 0204  

   Subsystem 4 - Part No: 8E0959802A
   Component: Tõrsteuer.HR BRM 0204  

8 Faults Found:
01134 - Alarm Horn (H12) 
            49-10 - No Communications - Intermittent
01368 - Alarm triggered by Luggage Compartment Switch 
            35-00 - -
01369 - Alarm triggered by Hood Switch 
            35-00 - -
01374 - Alarm triggered by Terminal 15 
            35-00 - -
01371 - Alarm triggered by Door Contact Switch; Driver's Side 
            35-00 - -
01035 - Electric Window Thermal Protection Active; Passenger 
            35-10 - - - Intermittent
00936 - Electric Window Switch in Front Passenger Door (E107). 
            27-10 - Implausible Signal - Intermittent
01562 - Rear right door 
            59-10 - Can't Unlock - Intermittent

-------------------------------------------------------------------------------
Address 56: Radio        Labels: 8E0-035-1xx-56.lbl
   Part No: 8E0 035 195 H
   Component: symphony II NP2    0410   
   Coding: 01000
   Shop #: WSC 74752  
   VCID: AC144B315D2EBE2FA9-5066

1 Fault Found:
00878 - Connection to Speaker Front Left 
            36-10 - Open Circuit - Intermittent

End----------(Elapsed Time: 05:39, VBatt start/end: 13.2V/13.1V)-----------
 
   #12  

drihos

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No part number on reluctor, came with the cams on the AWM head, actually used that diagram on the ross tech wiki on cam chain position notches and relative pre- oil pressure tension. It got me nervous because mine were not exactly as described, intake notch slightly to the right of cap arrow, exhaust notch exactly under roller, but slightly to the left of arrow. Will do compression test tomorrow and put those numbers up, will also read up on all mentioned topics, O2 sensors, maf baseline, injector spray patterns...about that, if I understand correctly to pull fuel rail and park injectors in mason jars? How do I actuate injection, jumper wire to fuel pump relay?
 
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Jack@European_Parts

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No part number on reluctor, came with the cams on the AWM head, actually used that diagram on the ross tech wiki on cam chain position notches and relative pre- oil pressure tension. It got me nervous because mine were not exactly as described, intake notch slightly to the right of cap arrow, exhaust notch exactly under roller, but slightly to the left of arrow. Will do compression test tomorrow and put those numbers up, will also read up on all mentioned topics, O2 sensors, maf baseline, injector spray patterns...about that, if I understand correctly to pull fuel rail and park injectors in mason jars? How do I actuate injection, jumper wire to fuel pump relay?

What about crank or cam sprocket key-way in relation to notch?

Procedures can found in RTFB!

http://wiki.ross-tech.com/wiki/index.php/Official_Factory_Repair_Information
 
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drihos

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Thank you Jef, for clarifying the three card monte routine, and stressing the importance of the dealer supplied coils. I burned up some of your time today, but I got good insight from that phone call. And thank you Jack for pressing hard on clear data. It'll take me a minute, but I'll learn it. Out of the frying pan and into the fire...
 
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drihos

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for the record, I haven't been a huge fan of the Bentley manual, had better luck on Audizine following along with Diagnosticator and Old Guy. Now I'm wondering if I just didn't know how to read that blessed book...
 
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drihos

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Exhaust cam gear TDC mark lined up neatly when damper pulley mark and notch were at lower cover and cam cap, when I rotated from crank bolt, but would slip back a couple of mm without me keeping pressure on the wrench. Intake cam gear wouldn't really follow along unless more rotation was added and I could see the tensioner moving/jumping up and down erratic from lack of consistent oil pressure. My injector harness is definitely brittle, and my coil harness only slightly less so. I was planning to splice in a new harness for each already. Just because I got the misfire to go away with coil replacement doesn't automatically mean I'm good to go. If anything it's got me more nervous. On my way to mech minutes now.
 
   #20  

drihos

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Then there's the powder coated valve cover to consider, I did grind down to the grounding post, but I mighta got hasty and not got through all the paint. I think if it was the timing it wouldn't have passed emissions the first time around the block, literally. I'm not going to worry about that yet, not until I know enough to run different maps. I was not nervous about turning the key, not nearly as much as my first timing belt swap. But I'm already down the rabbit hole, might as well have a look around.
 
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