Misfire Cyl 6 + Intake Manifold Flaps Stuck Open/Closed

B6/7 S4/RS4
#1

Well my first issues with my new to me RS4. :frowning: A few day ago I was driving my car, shut it off, it sat for about 45min, then when I fired it back up it seems to hesitate slightly. The CEL and EPC light came on. The car seemed to hunt around at idle slightly, but other than that drove fine and I didnt specifically notice a lack of power. I donā€™t have vcds yet so I parked the car for the last few days until I could get some help. Paid a guy $20 and he came with his Ross-Tech cable and we scanned codes, ran diagnostic checks, etc.

From what I can tell, cylinder 6 misfired back at 51,405kmā€™s. Funny because at that time, the CEL light did not come on. That would have been a couple weeks ago now. Ok, so fastforward to 51,871kmā€™s which was just the other day and I get Intake Manifold Flap; Bank 1 and 2 stuck open. Then at 51,903kmā€™s Check DTC Memory of ECU Number 2, Intake Manifold Flap; Bank 1 stuck open and stuck closed.

We then ran the diagnostic checks. The airbox flap opens and kind of toggles in the open position. Not sure if itā€™s supposed to fully open and fully close during this test? Anyways, my concern was the intake manifold flaps more than anything and when we tested them, they didnt move or click or do anything. I am not very familiar with these systems on my car yet, but I figure these arms should be cycling or something during this test, should they not? That has me concerned that something is causing these flaps to be stuck (carbon?) or maybe more likely, the system that operates both of these flaps is not sending the signal or is malfunctioning in some way. The other issue is the misfire on cyl 6. I donā€™t have the records to show it, but I was told by the previous owner than the coil packs and spark plugs were recently changed. Maybe he got his Indy shop to do the work instead of the Audi dealership he normally brought the car to. Iā€™m thinking something other than the spark plugs or coils caused the misfire.

Here are the logs

Address 11: Engine II Labels: 079-910-560-BNS2.lbl
Control Module Part Number: 8E1 910 560 J HW: 8E1 907 560
Component and/or Version: 4.2L V8/4V FSI ĀŖ0010
Software Coding: 01040009180F0160
Work Shop Code: WSC 93285 999 12144
VCID: 2D5B2A99B4805149F59-8078
3 Faults Found:

000768 - Random/Multiple Cylinder Misfire Detected
P0300 - 008 - - Intermittent
Freeze Frame:
Fault Status: 00101000
Fault Priority: 0
Fault Frequency: 1
Reset counter: 255
Mileage: 51405 km
Time Indication: 0

         Freeze Frame:
                RPM: 1414 /min
                Load: 54.9 %
                Speed: 11.0 km/h
                Temperature: 57.0Ā°C
                Temperature: 38.0Ā°C
                Absolute Pres.: 930.0 mbar
                Voltage: 13.589 V

000774 - Cylinder 6
P0306 - 008 - Misfire Detected - Intermittent
Freeze Frame:
Fault Status: 00101000
Fault Priority: 0
Fault Frequency: 1
Reset counter: 255
Mileage: 51405 km
Time Indication: 0

         Freeze Frame:
                RPM: 1414 /min
                Load: 54.9 %
                Speed: 11.0 km/h
                Temperature: 57.0Ā°C
                Temperature: 38.0Ā°C
                Absolute Pres.: 930.0 mbar
                Voltage: 13.589 V

008197 - Intake Manifold Flap; Bank 2
P2005 - 002 - Stuck Open - Intermittent - MIL ON
Freeze Frame:
Fault Status: 10100010
Fault Priority: 0
Fault Frequency: 1
Reset counter: 255
Mileage: 51871 km
Time Indication: 0

         Freeze Frame:
                RPM: 2613 /min
                Load: 23.5 %
                Speed: 85.0 km/h
                Temperature: 94.0Ā°C
                Temperature: 30.0Ā°C
                Absolute Pres.: 940.0 mbar
                Voltage: 13.716 V

2 Faults Found:

008196 - Intake Manifold Flap; Bank 1
P2004 - 002 - Stuck Open - Intermittent - MIL ON
Freeze Frame:
Fault Status: 10100010
Fault Priority: 0
Fault Frequency: 1
Reset counter: 255
Mileage: 51871 km
Time Indication: 0

         Freeze Frame:
                RPM: 2615 /min
                Load: 23.5 %
                Speed: 85.0 km/h
                Temperature: 94.0Ā°C
                Temperature: 30.0Ā°C
                Absolute Pres.: 940.0 mbar
                Voltage: 13.716 V

006435 - Please Check DTC Memory of ECU Number 2
P1923 - 008 -
Freeze Frame:
Fault Status: 01101000
Fault Priority: 0
Fault Frequency: 1
Reset counter: 255
Mileage: 51903 km
Time Indication: 0

         Freeze Frame:
                RPM: 0 /min
                Load: 0.0 %
                Speed: 0.0 km/h
                Temperature: 14.0Ā°C
                Temperature: 18.0Ā°C
                Absolute Pres.: 930.0 mbar
                Voltage: 11.811 V

2 Faults Found:

008196 - Intake Manifold Flap; Bank 1
P2004 - 002 - Stuck Open
Freeze Frame:
Fault Status: 01100010
Fault Priority: 0
Fault Frequency: 1
Reset counter: 255
Mileage: 51903 km
Time Indication: 0

         Freeze Frame:
                RPM: 1111 /min
                Load: 36.8 %
                Speed: 0.0 km/h
                Temperature: 31.0Ā°C
                Temperature: 23.0Ā°C
                Absolute Pres.: 930.0 mbar
                Voltage: 13.462 V

008198 - Intake Manifold Flap; Bank 1
P2006 - 008 - Stuck Closed
Freeze Frame:
Fault Status: 01101000
Fault Priority: 0
Fault Frequency: 1
Reset counter: 255
Mileage: 51903 km
Time Indication: 0

         Freeze Frame:
                RPM: 754 /min
                Load: 27.4 %
                Speed: 0.0 km/h
                Temperature: 42.0Ā°C
                Temperature: 23.0Ā°C
                Absolute Pres.: 930.0 mbar
                Voltage: 13.716 V

1 Fault Found:

008197 - Intake Manifold Flap; Bank 2
P2005 - 002 - Stuck Open - MIL ON
Freeze Frame:
Fault Status: 11100010
Fault Priority: 0
Fault Frequency: 1
Reset counter: 255
Mileage: 51903 km
Time Indication: 0

         Freeze Frame:
                RPM: 780 /min
                Load: 29.0 %
                Speed: 0.0 km/h
                Temperature: 47.0Ā°C
                Temperature: 24.0Ā°C
                Absolute Pres.: 930.0 mbar
                Voltage: 13.843 V

Hope thatā€™s enough information for you guruā€™s to work with and provide some guidance and possible solutions. Thankfully the guy with the VCDS cable has offered to come back free of charge if I need to do any further testing or checks on the car.

#2

those flaps can stick open with carbon, but thatā€™s not the only reason.

never cleaned?

#3

Could it be the potentiometers on bank 1 and 2? Just throwing it out there.

#4

Not that I know of. 51k kmā€™s on it.

I agree they could stick open with carbon, but you would think during the vcds diagnostics checks I would have seen the arms attempting to move or something.

Are those what turn the flap arms/flaps? If so, then itā€™s possible, but if they are both not working, that leads me to believe that itā€™s some system that runs both of those that is the culprit.

#5

The first thing to do is consider getting a vagcom that way you can do some of your own testing.

Secondly of you cleared the codes see if the flap codes come right back.

As for the misfire on cylinder 6 pull the cylinder 6 plug and coil pack and move it to the number 4 spot. See if you get misfires on the cylinder you moved the coil pack to. If you do thatā€™s a easy fix. If the misfire still stays on cylinder 6 you know you have a bigger issue.

#6

Getting a vagcom cable is in the works. Debating the standard cable or hex-net wifi cable.

Yes the flap codes come right back after theyā€™re cleared.

Can I assume based on the fault priority of 0 on the various fault codes, that its safe to drive the car still while I figure out the issue?

I will swap the coils around and see what happens, thanks.

#7

If the code comes back right away then you definitely have a issue. Unplug the battery and plug it back in. With the hood popped and someone in the driver seat have someone key up the car. Look at the linkages on the intake they should move back and forth to test themselves

#8

Fault priority 0 means undetermined or something rather than no problem or ZOINKS!

#9

Sent you a pm. Iā€™ll give it a try in the next couple of days when I have time. Something tells me the linkages likely wonā€™t move during this test seeing as they didnā€™t move at all when I did the vagcom diagnostics tests. I could be wrong though.

Iā€™m wondering if this flap issue might be a dead solenoid, just because there was no noise or ticking at all when I did the tests before. If there was a ticking noise it would lead me to believe that the solenoid was fine but there was a vacuum issue or one of the actuators was dead, causing the flaps to not move. Like I said, no ticking noise on mine so maybe the actuators arenā€™t even getting a signal.

Iā€™m still speculating at this point, but Iā€™m researching what I can and Iā€™ll be doing some further tests soon.

Iā€™m trying to resist the urge to just bring it in to the dealer or one of my local indy shops to ā€œjust fix itā€. I want to start driving my car again, but I think this is a good opportunity to learn about my car and possibly fix it myself.

#10

Letā€™s start with this. Take a picture of the front linkages and post it here. Itā€™s common for the RS4 intake to break itā€™s linkage. We can check that easy with just a picture

#11

Two pics from each side

https://www.dropbox.com/sc/u1uvflesy7zy4hu/AAAbwWVGquXe0WYCMysNAQuOa

They dont look broke to me.

Iā€™ll upload the actual pics on the site once Iā€™m on my computer.

#12

From what you can see there itā€™s intact it could be another part of the system. I know itā€™s hard to get a good picture of the front of the intake manifold but if you can get a full picture that might show more.

#13

Unable to get a picture from the front of the intake. It was difficult enough to get the two linkage pics.

On a side note, the EPC light went out a couple days ago, and a day later the CEL went out. Hasnā€™t come on since. I have been driving the carā€¦maybe thatā€™s all it needed.

I will be clearing the codes in memory and would like to investigate further as to what the issue is/was.