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

  1. #1
    Verified VCDS User drihos's Avatar
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    B6 A4 1.8t quattro rebuilt head multiple misfires cyl#2 and #3

    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: Tőrsteuer.FS BRM 0204  
    
       Subsystem 2 - Part No: 8E1959802E
       Component: Tőrsteuer.BF BRM 0204  
    
       Subsystem 3 - Part No: 8E0959801A
       Component: Tőrsteuer.HL BRM 0204  
    
       Subsystem 4 - Part No: 8E0959802A
       Component: Tőrsteuer.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...

  2. #2
    Verified VCDS User drihos's Avatar
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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. #3
    Ross-Tech Employee Jef's Avatar
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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.
    Jef
    Ross Tech Support Team, Alpha Squad
    Auto-Scan, learn it, love it, live it... then check the fuses.

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    NostraJackAss Jack@European_Parts's Avatar
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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?
    Last edited by Jack@European_Parts; 03-20-2020 at 03:45 PM.
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    Verified VCDS User drihos's Avatar
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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.

  7. #6
    NostraJackAss Jack@European_Parts's Avatar
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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?
    European Parts Emporium/Performance / Immobilizer Solutions EPE
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    Specializing in Custom Services IE: "welding-fabrication" / EPA-SMOG Update or Pass-Thru-Programming / Data Transfer / Immobilizers & OEM Quality Parts
    Above Magic! No Written record, AUTO-SCAN or Appointment = NO HELP!
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  8. #7
    Verified VCDS User drihos's Avatar
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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.

  9. #8
    Verified VCDS User drihos's Avatar
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    no i had not

  10. #9
    Verified VCDS User drihos's Avatar
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    but i was told the engine should be warm for a comp test

  11. #10
    NostraJackAss Jack@European_Parts's Avatar
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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/showthr...lling-a-bellt!
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    Above Magic! No Written record, AUTO-SCAN or Appointment = NO HELP!
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