New cylinder block - 2 weeks left on warranty!!!

[jimbosale]

Took the RS4 into the garage as I had a engine warning light come on. Diagnostics confirmed it was a failed solenoid for the secondary air. Took the car into Worthing Audi and had a phone call asking whether the car was using a lot of oil!!! When ask why, I was advised that while changing the solenoid they had found a lot of burnt oil under the car. Further diagnostics found that the engine was 'fluttering' at 1700rpm a known sign that the there may be a problem with the cylinders. Cylinder head was removed and 3 of the bores had started to score and polish. 3 weeks later and I have a new cyclinder block and remapped engine. Apparantly to avoid this problem the engine has to run 2-3 degrees hotter. All work done under warranty with only 2 weeks left!!!!!! Car had done 38,000 miles. All credit to Worthing Audi, the car had only gone in for a cheap solenoid replacement and ended up as a £9k job!!! If this hadn't been picked up I could have had a nasty bill in 6 months time.

[PetrolDave]

Apparantly to avoid this problem the engine has to run 2-3 degrees hotter.

Hmmm.... not sure I see how that would make a difference?

Did they give you any proof of this statement?

Not seen anyone else post this issue either on forums here or in the US.

[SR71]

jimbo,

Can you expand on the symptoms of a "fluttering" engine?

Are you talking about a "fluttering" mass flow rate?

[jimbosale]

I am not too sure. It is something to do with the bores being silicon carbide lined and I believe is not uncommon. It only happens to cars in the UK and is not has not been a problem in Germany. I guess something to be aware of.

[mac4RS]

Apparantly to avoid this problem the engine has to run 2-3 degrees hotter.

Jimbo, I'm currently having probs with my motor...thro' many discussions with my dealer, it was mentioned that I'm running ECU version 0080. He stated that version 0090 was for motors that needed to run at higher temperatures due to lots of town driving etc...? (still unsure what he really meant)

Is your remapp using version 0090.

[silverRS4]

Can you expand on the symptoms of a "fluttering" engine?
Are you talking about a "fluttering" mass flow rate?

I'm sure the flutter Audi is referring to is piston ring flutter. It usually happens at high RPMs under low engine loads. In these situations, there isn't enough cylinder pressure to keep the rings square to the bore. This results in more blow-by and higher crankcase pressure. This phenomena shouldn't have any affect on the mass-air sensor readings. I believe high RPM flutter is normal. If the ring flutter happens at lower RPMs, bore wear will be accelerated - which is apparently what happened to jimbo's engine. Why exactly? Hard to say...

[jimbosale]

I am not sure what ECU version software they remapped to. Is there are an easy way to tell? It sounds like the same thing though - lots of stop start driving which apparently is causing the problem (mind you I do 60 miles a day and this isnt town driving - mostly country roads).

[WBRS4]

jeez! where do these problems keep coming from??

hope everything works out fine for you

[jimbosale]

Bearing in mind the amount of work I have had done on this car - engine has bascially been rebuilt and numerous components changed do you think I should extend the warranty?

[rsowneraudi]

the 'flutter' refered to is probably when you hold the revs steady at between 1,500 and 1,800 revs, you will find that it will not feel smooth i.e a flutter

[SR71]

What are we talking about here?

* The engine refusing to maintain constant revs between these limits?
* The actual car vibrating/fluttering at these revs as result of the issue?

Thanks.

[jimbosale]

i believe that due to the problem with the cylinders the engine was 'fluttering' at the rev range. Had the latest ecu software flashed and the engine is running well. RPM is around 1600 on cold start. Apparantly this helps avoid future problems by warming the engine quickly.

[rsowneraudi]

the engine will hold a steady rpm but you will feel a 'vibration' through the vehicle and you will hear the slightly different engine note