Rattling Exhaust Heatshield

[toasty]

So I guess most people here know that the early S4s had problems with loose exhaust heatshields causing a rasping rattling noise at various engine speeds.

I've noticed recently that mine has been getting slightly worse and whist not noticable in the car with the windows shut, if the windows are open then it does notice quite a bit.

Audi's stance on it seems to be, that a) it isn't covered by warranty and b) it costs > £1k as it is an engine out job to swap the manifolds (16hrs labour)

I sold my S4 on the weekend, and the guy didn't notice the noise, but I don't want to sell him the car with the rattle if at all possible, as I want him to enjoy the car, and have a trouble free ownership.

But I don't want to spend loads getting it fixed either.

Had a look down the back of the engine today at work and it would seem that you can see the heatsheilds on both sides of the V quite easily, and also I can see at least 2 bolt heads on each on that would be gettable with a long socket set and a flexi bit. (perhaps even more if I removed the air intake section and the coolant header tank)

Looking at an image of the S4 engine:

I've highlighted in red the bit I think I'm looking at.

Does anyone know if this is infact the manifold heatsheild that is renowned for rattling, and if tightening up the bolts will do any good?

Also, it would seem that removing the engine undertray would reveal more of the sheild (at least from looking at the image it seems that the sheild goes quite a way down)

If anyone here is an expert on this part of the S4 engine then I'd appreciate some advice.

For what it's worth, I reckon it's a pretty bad show that the warranty doesn't cover this part of the engine.

I'm hoping that given a few hours and a good mechanic to help me out it should be possible to cure this problem for the new owner, and save myself the thousands audi would want to replace it.

As always, any advice gratefully received.

[toasty]

....found a better picture: (again, what I think is rattling is in red)

[snbS4]

Dan
I too apparently have this problem but was told by AMD that although quite common, it's still a big job as one of the brackets is mounted to the turbo. This bracket 'unwelds' itself and the rattling begins after about a minute of running.
My dealer has quoted £3,100 for new turbos 'while they are at it'! [img]images/graemlins/shocked.gif[/img]
I am also unconvinced and am hoping to have a real good look-see on my friend's ramp in the next few weeks (if I can get a day off) while he does the interim oil & filter change.
Mine seems to come from the RHS and as the weather warms up [img]images/graemlins/3flypigs.gif[/img] I might have the window open more often.
One of the chaps on AudiWorld removed the heatshield altogether on his A6 2.7T and others bend them out of the way! [img]images/graemlins/1syellow1.gif[/img]
Not sure if this helps at all really. [img]images/graemlins/crazy.gif[/img]
Rgds
Simon [img]images/graemlins/s4anogaro.gif[/img]

[toasty]

That is helpful, thanks Simon.

So how easy is it to bend them out the way I wonder....?

As for mounting on the turbo, that's interesting.

I'm hoping that removing the undertray will allow access to the shield and Ican sort something out.

[Mik]

Dan

I had the same issue which got gradually worse. I had opinions from several Audi dealers and AMD. They all agreed that my symptoms were caused by the heatshield rattle which was a problem on early cars (though not covered by warranty). I did however manage to get 30% discount from Audi by making 150+ calls to customer services... on the repairs which Audi claimed required both turbos and heatshields - Audi claimed I could just change the heatshields but that the problem would then reoccur unless the turbos were changed too. Apparently the turbos were causing excessive heat resulting in the brackets unwelding from the turbos.
To begin with I told my self I could live with the rattle, but after driving with it for about a year it was really quite loud - you always pay attention when your mates go "uhhh....whats that rattle..." [img]images/graemlins/24430-audibash.gif[/img]

In the end...I gave in and changed both manifolds and turbos [img]images/graemlins/shocked.gif[/img]

Mik

[samtheman]

oh dear.. mine's got a bit of a rattle when i move off slowly, but only when its cold. after a few miles it goes away.. sounds like its coming from the exhaust underneith, but could be the heat sheild i spose.. [img]images/graemlins/033102bad_1_prv.gif[/img]

[sitas3]

So Guys, why is this not covered by Warranty? surely this is a defect??

What excuse did Audi pull out of their bag for this one?

[dog]

I had a lot of rattles in my Allroad and it was all fixed under warranty. They had to unfold and refold something about the heat shields. I'll try to find out more.

[snbS4]

I should also add that I have made several phone calls to Audi only to find out that there was a workshop programme of some kind but not an actual recall.
My frustration was that I was delayed in collecting the car while waiting for the Dealer to carry out the throttle and other bits mods which I am sure they said included heatshields. Unfortunately that was some years ago and the Dealer has changed computer systems so the records are not available [img]images/graemlins/033102bad_1_prv.gif[/img]
Anyway Audi won't entertain a contribution towards the cost and as the performance is strong enough I'll see if I can do anything myself!
Simon [img]images/graemlins/s4anogaro.gif[/img]

[toasty]

Have tried to get in touch with Jim De Arras on Audi World, he seems to be the knowledge on this particular problem.

In any case I'm going to take a look on Saturday with my mechanic friend James.

Obviously as I am selling the car, I'm not looking to just bodge the car up, I reckon with a bit on ingenuity I can fabricate a solution better than the original [img]images/graemlins/thumb.gif[/img]

[toasty]

Well to be honest the results were amazing.

just a case of tightening the hose clamp at the bottom and the bolts at the top. Result..... no rattle!!!!

I think my friendly Audi Stealer wanted about 3 grand to fix it!

[Bushy]

Well done Dan, good to see a true gentleman at work

I hope you still keep in touch, even without the S4, have you found another car yet?

Well done and good luck

[wazza]

have you found another car yet?

depends on your definition of *car* Steve?

[toasty]

It's got a turbo so it must be fast... !
Sadly it's a diesel, and no it isn't fast. (306 HDi)

I'm just looking forward to when I have a garage