Lets play "Fix it or Scrap it"

I’m sure we’re all gonna reach this at some point, my time is coming soon.

I’ve got a not too trusty, but still loyal, 2007 S6 I picked up in 2014, at 85K miles. In the past 6 years I’ve put on about 30K miles all around the world––it’s had the good fortune to spend time as diplomatic POV in southern Europe and now SE Asia. (I know, LHD in a RHD world)

Our current post is wrapping up this summer and I need to decide if I should ship it back to Europe for another 3 years, or just scrap it (somehow). On the plus side, the car is actually in pretty good cosmetic condition. It didn’t hurt that I got a new interior from an insurance payout on mold.


(Pay no attention to the lil dent in the back… PDR?)

With the addition of streaming BT and a perfect spot for a phone holder/Google Maps, It feels like a new car that checks all the luxe boxes. Despite the gutted intake, it’s also fun to drive. Especially on long family road trips.

The problem is that the car is 14y old, gets about 11/18 MPG (which I’m slightly ashamed of), and has a number of unexplained electrical quirks, a few mechanical issues, and a host of unknowns lurking simply because of age. All of which I will get to below.

But my choice is:

  1. to ship it to Europe, the land of $4-6/gallon gas depending on whether I get a tax rebate, for 3 more years;
  2. ship it back to the USA, where it will be in the hands of someone who will never know the joys of this forum;
  3. scrap it (somehow) in SE Asia and ship a TBD, new-to-me (and younger) used car from the US to Europe in it’s place; or
  4. buy the same used car in Europe and sell it in 3 years when we leave.

If I knew I could spend $2K in repairs and get 3 good years from this car, I would definitely keep it. But the unseen bogeys lurking in the dark have me worried. I’ll explain the ones I’ve uncovered in the posts below.

Let’s start with the unknown electrical gremlins––ones that I thought I had resolved a few years back, but just recently began to rear it’s ugly head. (see: Intermittent codes - diagnose electrical or mechanical problem?)

  • P0221 - Throttle Position Sensor B (G188), Circuit Range / Performance
  • P1564 - Throttle Actuator (J338), Under-Voltage during Basic Setting
  • P0023 - “B” Camshaft Position - Actuator Circuit/Open Bank 2
  • P0024 - “B” Camshaft Position - Timing Over-Advanced or System Performance Bank 2
  • P1060 - Bank 2, cam shaft adjustment discharge opening, interruption

Years ago, my mechanic had pulled the cam solenoid valve and it checked out fine with a DMM and with voltage. So he cleaned all the connectors, and also added a zip tie to the TB connector. (see P0221 - Throttle Position Sensor B, Throttle Body Connectors?) It seemed to do the trick, until just recently.

Then this happened: Whistling at idle. It was after this past Christmas break––the car was left alone for a month, and I’m sure some seals were drying out. Not only that, but I had to jump the car to get it started. It took awhile, but I finally found the source of the leak at the base of the Right/passenger Throttle Body. I patched it with some RTV while I waited for a new TB gasket, and the whistling went away(!) Shortly thereafter, I got an EPC fault, limp mode, and the codes mentioned above.

After letting the car rest and clearing the codes, the car would drive just fine. But eventually, the EPC fault always came back. Now that I’m paying attention to it, I notice that it often seems to happen when the battery is low. The car is not getting much action these days, especially not during the Covid19 lockdown. I have the battery meter on the MMI screen and I saw it down to 5% a couple of times.

So maybe it’s a battery related issue, or maybe it’s a bad electrical connector. But in between faults, the engine seems to be running smoothly without any misfires. However, I do recall patching the T14h 14-pin brown connector on the engine harness a number of years ago, so it makes me wonder if there isn’t a new/unseen electrical issue (see Engine out thread)

Here’s a photo from that post for your viewing pleasure:

Moving on to the High Pressure Fuel Pumps, since I just posted again here: HPFP leak at the fuel pressure regulator valve

The quick summary is that one mechanic spotted signs of an obvious HPFP fuel leak when I took the car in for an inspection and investigation into a nagging oil leak. Here’s the photo for quick reference:

I have no idea how long that stain has been there. But I wiped it clean and swapped the tip of the fuel pump by the connector to check for fuel vapors. For the next few weeks, the HPFP was smelling fresh and clean! So maybe I can call it a leftover from a prior service???

But after a few weeks in covid19 lockdown, as the car mostly sat in it’s parking space, I recently checked again. Now I can swab the tip of the connector and actually smell fuel vapors. However, there is still no overt leak.

Can anyone more familiar with the HPFPs tell me if Is this normal? or a sign of impending failure?

Speaking of oil leaks, I had a persistent drip below my car. It was bad enough that the maintenance team at my complex started to put sheets of cardboard under my car. ouch! Still, nothing an occasional top-up couldn’t fix.

I finally got around to doing something about this leak by taking the car to a German/Exotic car specialist on the other side of town. He gave me a writeup for a full inspection, but said the oil was coming from the back of the engine by the firewall and he couldn’t say more because there was no room back there to see anything. But his suspicion was that it was a leak around the camshaft covers and that the timing chain may need to be serviced. That’s an engine out procedure and I didn’t really sign up for that.

However, I did spend some time trying to determine if the timing chain was on it’s way out with this post: S6 Rattle - timing chain going?. The general consensus is that I was probably fine, so it’s not worth an engine out just to check the camshaft covers.

In the end, I was disappointed with the diagnostic abilities of my German car mechanic. I took another shot with a local guy just a long walk from my home who had no problem doing work by the hour in dribs and drab. He came up with this incremental plan:

  1. reseal the oil sump pan and install a new oil sensor gasket. (cheap and easy to do)
  2. take the front end off and replace the front crank seal. peek under the intake with a borescope I purchased to see if there was also a leak by the oil filter.
  3. remove the IM and replace the oil filter gaskets, (and maybe do a carbon clean and IM mod while we’re there)

Resealing the oil sump pan helped, but the leak was still there. I’m just in the middle of 2) replacing the front crank seal, and it appears that this was a likely culprit. Here’s the before/after:

I think that will definitely slow down the leak.

He said the accessory belt was collateral damage from oil contamination. But we also discovered that the belt tensioner (above) had a small dent in it that just barely clicked on every rotation. They straightened it out with some pliers so it now spins freely, but he says there is still a slight vibration as it spins, maybe it’s out of balance and the bearings are going out. I can’t replace it yet because the part is not available locally.

The photos above are from the borescope I got from Amazon, looking under the IM at the oil filter “flange”. You can see signs of oil sludge, so it’s probably leaking from there as well.

Here’s a photo when I was in there Oct-2015 for the same thing. By comparison, this leak doesn’t seem as bad.

But before we remove the IM to deal with the oil filter housing, I have another problem with the cooling system. Apparently, the upper intake hose to the radiator has gotten brittle at the quick connect, and the bypass outlet has broken off (see below). Again, the part is not available locally, so we might have to hack this with a metal connector and hose clips.

Also, the upper inlet to the radiator is turning brown and brittle to the touch (below). I think that is a candidate for replacement. The lower outlet hose on the other side is also starting to bulge a little and could also be on the list.

My mechanic also noticed a leak at the high pressure Power Steering hose when he pulled down the protective cover (below). I hadn’t noticed any problems with the steering, but since we can get a replacement hose locally (plus they are $$$) I’m gonna have to keep PS fluid on my top-up checklist.

That’s about it for the new discoveries with the front end off. I’m not sure if I can leave the car at his shop for 10-14 days (as is) it takes to get replacement parts from Amazon. But I gotta decide how what to replace while I’m in there. And I’m probably gonna save the IM for another visit.

Order your parts on ebay or search google shopping with part numbers. The leak sounds like camshaft covers but hopefully it’s not that because that’s why my car needed an engine out service, which turned into much more. Hopefully your leak isn’t that and you can get many more miles without any issues.