Time for More Maintenace-Belt, Pulleys, Waterpump, and More Oil Leaks!

A6 All/ S6 All
#1

Been away for awhile, busy collecting parts for the my next maintenance activity. The beast is leaking oil like the Exxon Valdez, need to try to reduce the flow. I’ve done the oil filter housing gaskets and the valve covers.
Going to remove the front end and replace the following:

  • Belt
  • Tensioner assembly
  • Idler pulley
  • SAI plates
  • JHM Crank Pulley
  • crankshaft oil seal
  • Water pump
  • Oil cooler orings
  • reseal oil pan

What else should I do while I have the front end off?
Looking for feed back on any clamps, gaskets, orings I should have on hand when I remove the radiator, etc.
I’ve done the carbon clean, added JHM spacer, wow!, really brought the throttle response back!
New valve cover gaskets, plugs and coils a bout 3 months ago.
Have the JHM tune ready to flash/install after the service, Exhaust is next.
Car has 120K, getting it ready for the next 100K.
I’ve only had the bumper off to install my RS6 grill, nothing deeper than that on the front. Any thing I should be aware of when removing the support, lights, etc?
Thanks in advance!

.

#2

it’s pretty straightforward, especially if you did the other work yourself - pulling the intake is way more of a PITA than the front IMO. Granted, I’ve only put the front end into service position and didn’t pull the whole core support off so YMMV

#3

Looks like you’re on the right track, I would only add maybe a new thermostat while you’ve got the front end off

#4

Thanks for the feedback, I believe the new waterpump assembly comes with a thermostat, I’ll have to check that.

#5

Ah ok, you may be correct

#6

http://audirevolution.net/addons/albums/images/5400720.jpg

Waterpump assembly comes with new thermostat, guess it should for $335.

Never installed a crank seal before, any pointers?

Thanks!

#7

The 5.2L surgery began on Saturday. I’ve had the bumper cover off before, however the top support bolts were very rusty, would recommend hitting them with some PB before trying to remove. Ended up spinning the nut on one and having to cut off the head.

http://audirevolution.net/addons/albums/images/841775390.jpg

The only other major issue on disassembly was the aux rad hose connection, ended up breaking the slip on fitting

http://audirevolution.net/addons/albums/images/854661997.jpg

Got the front end off to find this

http://audirevolution.net/addons/albums/images/48392120.jpg

http://audirevolution.net/addons/albums/images/844995274.jpg

I’m guessing most of my problem is the Oil Cooler O-rings.
Got the alternator off and the oil cooler off. The oil cooler is a bitch, or at least that lower rear bolt is a bitch, to remove with engine in the car. Not sure how I’m going to get that one back in!

The oil above the crank pully was pretty dry, I’d fixed the oil filter housing doing the carbon clean and spacers. The crank seal looks pretty dry overall. Not sure of the pattern on the engine, guessing oils been getting one the pulley and the centrifugal force sprayed it in the circular pattern around the front of the engine.

http://audirevolution.net/addons/albums/images/200037662.jpg

Have a new crank seal to put in. Never installed a crank seal, anything I need to know?
The seal comes with a plastic guide that fits over the crank, Looks pretty straight forward, just clean and lube and press in evenly.

More pics to come

#8

great pics! really awesome to post them up. Makes me think I should have taken more pics.

No doubt will be helpful to someone else.

As for the rad hose, it’s a pain to find the replacement, just like the rad. I ended up getting the correct radiator and hose from ECS.

Rad hose part# is 4F0121471D

https://i.imgur.com/DqMJAJD.jpg

#9

Thanks, more to come.
I’ve got a rad hose on order from Jil Ellis in Atlanta, they have a pretty nice online parts ordering site with all the ETK parts diagrams and 25% off list on everything. I didn’t check on availability, I’ll give them a call and find out.

#10

Great job so far! I did the oil cooler a few months ago. My leak was bad, but not nearly as bad as yours.

I snaked a long extension with a universal joint on the end though all of the hoses and wire looms to get to that back bolt. If you shine a flashlight in there, you can see the end of the torx socket engage the bolt head. I was stressed too, but it ended up being pretty easy.

#11

Hey guys, been awhile, the S6 has been running good with no leaks. During the last surgrery I added the SAI delete and JHM Tune, amazed at the performance increase and change in sound. Surprised that it changed the engine/exhaust sound as much as it did, adding a nice growl at about 3200-3400 rpm. Can only imagine what adding the cat back exhaust would do. It’s a little harder to drive in sport, need to be careful of the lurching and bucking. I may need a new IM, not sure if that could be part of the problem.

I’ve got more pictures of my work to post, just been crazy busy with work. Hope to get those up soon.

The car has developed a misfire for the first time! Pulling codes tonight, however I know that I didn’t replace/clean the injectors and was wondering if JHM still offers this service. Brief surf of their site didn’t show anything but new injectors. Seems to me they used to have a $600 service to clean and test at working pressure?

Will pull codes and get back with more info.

Thanks!

#12

Pulled Codes, found the following:

4 Faults Found:
001110 - EVAP System
P0456 - 001 - Very Small Leak Detected - Intermittent
Freeze Frame:
Fault Status: 00100001
Fault Priority: 2
Fault Frequency: 2
Reset counter: 255
Mileage: 202389 km
Time Indication: 0
Date: 2018.10.30
Time: 17:48:08

         Freeze Frame:
                RPM: 2587 /min
                Load: 21.6 %
                Speed: 119.0 km/h
                Temperature: 76.0°C
                Temperature: 10.0°C
                Absolute Pres.: 980.0 mbar
                Voltage: 13.589 V

000135 - Fuel Rail/System Pressure
P0087 - 002 - Too Low - Intermittent - MIL ON
Freeze Frame:
Fault Status: 10100010
Fault Priority: 2
Fault Frequency: 1
Reset counter: 255
Mileage: 203305 km
Time Indication: 0
Date: 2018.12.30
Time: 13:59:57

         Freeze Frame:
                RPM: 678 /min
                Load: 25.9 %
                Speed: 6.0 km/h
                Temperature: 72.0°C
                Temperature: 18.0°C
                Absolute Pres.: 970.0 mbar
                Voltage: 13.843 V

005715 - Please check DTC Memory of ABS Controller
P1653 - 008 - - Intermittent
Freeze Frame:
Fault Status: 00101000
Fault Priority: 2
Fault Frequency: 1
Reset counter: 255
Mileage: 203305 km
Time Indication: 0
Date: 2018.12.30
Time: 14:07:52

         Freeze Frame:
                RPM: 0 /min
                Load: 0.0 %
                Speed: 0.0 km/h
                Temperature: 78.0°C
                Temperature: 26.0°C
                Absolute Pres.: 970.0 mbar
                Voltage: 8.001 V

006435 - Please Check DTC Memory of ECU Number 2
P1923 - 008 -
Freeze Frame:
Fault Status: 01101000
Fault Priority: 2
Fault Frequency: 1
Reset counter: 255
Mileage: 203308 km
Time Indication: 0
Date: 2018.12.31
Time: 10:26:09

         Freeze Frame:
                RPM: 0 /min
                Load: 0.0 %
                Speed: 0.0 km/h
                Temperature: 16.0°C
                Temperature: 14.0°C
                Absolute Pres.: 960.0 mbar
                Voltage: 11.430 V

Address 11: Engine II Labels: Redir Fail!
Part No SW: 4F1 910 562 A HW: 4F1 907 552 B
Component: 5.2L JHM/V3 9XSI ª0010
Revision: 5HH02— Serial number:
Coding: 01050009190F0160
Shop #: WSC 24103 444 13994
VCID: 234FF0E4E2B9BF52E6-8076

7 Faults Found:
000768 - Random/Multiple Cylinder Misfire Detected
P0300 - 001 - - MIL ON
Freeze Frame:
Fault Status: 11100001
Fault Priority: 2
Fault Frequency: 3
Reset counter: 255
Mileage: 200420 km
Time Indication: 0
Date: 2018.09.30
Time: 17:17:43

         Freeze Frame:
                RPM: 671 /min
                Load: 36.1 %
                Speed: 2.0 km/h
                Temperature: 46.0°C
                Temperature: 44.0°C
                Absolute Pres.: 980.0 mbar
                Voltage: 12.827 V

000775 - Cylinder 7
P0307 - 008 - Misfire Detected - Intermittent
Freeze Frame:
Fault Status: 00101000
Fault Priority: 2
Fault Frequency: 2
Reset counter: 255
Mileage: 200420 km
Time Indication: 0
Date: 2018.09.30
Time: 17:17:43

         Freeze Frame:
                RPM: 671 /min
                Load: 36.1 %
                Speed: 2.0 km/h
                Temperature: 46.0°C
                Temperature: 44.0°C
                Absolute Pres.: 980.0 mbar
                Voltage: 12.827 V

000771 - Cylinder 3
P0303 - 008 - Misfire Detected - Intermittent
Freeze Frame:
Fault Status: 00101000
Fault Priority: 2
Fault Frequency: 2
Reset counter: 255
Mileage: 200420 km
Time Indication: 0
Date: 2018.09.30
Time: 17:18:47

         Freeze Frame:
                RPM: 681 /min
                Load: 22.7 %
                Speed: 0.0 km/h
                Temperature: 56.0°C
                Temperature: 42.0°C
                Absolute Pres.: 980.0 mbar
                Voltage: 13.335 V

000773 - Cylinder 5
P0305 - 001 - Misfire Detected - MIL ON
Freeze Frame:
Fault Status: 11100001
Fault Priority: 2
Fault Frequency: 1
Reset counter: 255
Mileage: 203305 km
Time Indication: 0
Date: 2018.12.30
Time: 14:00:11

         Freeze Frame:
                RPM: 853 /min
                Load: 24.7 %
                Speed: 5.0 km/h
                Temperature: 73.0°C
                Temperature: 18.0°C
                Absolute Pres.: 970.0 mbar
                Voltage: 13.589 V

004874 - Cylinder Disabling
P130A - 001 - - Intermittent
Freeze Frame:
Fault Status: 00100001
Fault Priority: 2
Fault Frequency: 2
Reset counter: 255
Mileage: 203305 km
Time Indication: 0
Date: 2018.12.30
Time: 14:00:50

         Freeze Frame:
                RPM: 3275 /min
                Load: 56.8 %
                Speed: 44.0 km/h
                Temperature: 73.0°C
                Temperature: 15.0°C
                Absolute Pres.: 970.0 mbar
                Voltage: 13.716 V

005715 - Please check DTC Memory of ABS Controller
P1653 - 008 - - Intermittent
Freeze Frame:
Fault Status: 00101000
Fault Priority: 2
Fault Frequency: 1
Reset counter: 255
Mileage: 203305 km
Time Indication: 0
Date: 2018.12.30
Time: 14:07:52

         Freeze Frame:
                RPM: 0 /min
                Load: 0.0 %
                Speed: 0.0 km/h
                Temperature: 78.0°C
                Temperature: 26.0°C
                Absolute Pres.: 970.0 mbar
                Voltage: 8.001 V

000772 - Cylinder 4
P0304 - 001 - Misfire Detected
Freeze Frame:
Fault Status: 01100001
Fault Priority: 2
Fault Frequency: 1
Reset counter: 255
Mileage: 203305 km
Time Indication: 0
Date: 2018.12.30
Time: 14:08:27

         Freeze Frame:
                RPM: 1073 /min
                Load: 24.3 %
                Speed: 13.0 km/h
                Temperature: 71.0°C
                Temperature: 20.0°C
                Absolute Pres.: 970.0 mbar
                Voltage: 13.843 V

Replaced all the coils and plugs and carbon clean clean within the last 5K miles.

High pressure pump?
Read something about a purge valve?
Thanks for any suggestions!

#13

The JHM tune really transforms the car. Now you get to see more of what people are talking about. The difference in the sound is the JHM tune moving the camshafts for better performance.

The LOW rpm can be a taste tricky as there is no TQ restriction. So there are massive gains where before the ECU would kill all the TQ.

The misfire would make sense if its was a fuel pressure issue. You have an evap code as well. Check your LTFT data that should help tell you more. And you are right you really need to be thinking injectors soon as well.

#14

The fuel issue might simply be a bad gas. Had the same code few weeks ago after filling up at some random gas station. Since then fueled twice at my regular gas station and code has not come back

#15

[quote=“justincredible,post:13,topic:9850”]
The JHM tune really transforms the car. Now you get to see more of what people are talking about. The difference in the sound is the JHM tune moving the camshafts for better performance.

The LOW rpm can be a taste tricky as there is no TQ restriction. So there are massive gains where before the ECU would kill all the TQ.

The misfire would make sense if its was a fuel pressure issue. You have an evap code as well. Check your LTFT data that should help tell you more. And you are right you really need to be thinking injectors soon as well.

Please remind me what the LTFT data is :slight_smile:
I havnt had to use my vagcom for a couple years and I’m rusty, which is a good thing!
I was going to pull some data using the measuring blocks, however I dont remember where I can find the reference values. Are they in the manual somewhere? I have the Bently on CD
Or can I find them on the Ross Tech site?
Thanks!

#16

Any suggestions for finding reference values for fuel pressures?

#17

VCDS measuring blocks group 140 gives both your target and actual fuel pressures.

#18

Thanks!

#19

LTFT = Long Term Fuel Trims.

That tells you how the car is trimming fuel. - its pulling out fuel and positive is adding fuel.

Remember you have two ECUs so you will have to check both ecus for the values. I know on a standard non twin ECU its 032 and 034. Look in the 30 range and see what pops up. That should help get you in the right range. Just make sure not to clear the codes before you search. If you clear the codes the fuel trims will reset.

#20

Thanks, hopefully will have a chance to dig into this next week!