pb moteur 4.2 .pdf



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Titre: pb moteur 4.2
Auteur: lionel

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V6/V8/V10 FSI, metallic knocking noises from engine compartment(2015932/15)

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Connection offline
Technical product information
V6/V8/V10 FSI, metallic knocking noises from engine compartment

Transaction No.: 2015932/15
Release date: 24-Jul-2012

Customer statement / workshop findings
Hard metallic knocking noises from the engine at idle speed, particularly with cold engine. The noises
are particularly noticeable at a cold start (during the cat heating phase) after the drop from increased
to normal idle speed. In an advanced stage increased oil consumption, blue smoke, erratic idle speed
and even misfiring and compression loss are possible.

Technical background
An extreme load in the running-in phase of the engine can cause abrasion on the running surfaces of
the cylinder. This abrasion can widen the cylinder pipe and in an advanced stage tilt the piston in the
cylinder pipe.

Production change
Changes in the cylinder pipe from engine numbers:
V8/V10 engines
S6

V10

BXA 008214 improved for Parts

A6

V8

BVJ 027981  WAUZZZ4F2AN084338

V8

BVJ  028181  WAUZZZ4E8AN009263

V10

BSM  improved for Parts

Audi S5

V8

CAUA 023205 WAUZZZ8T6AA079621

Audi Q7

V8

BAR  045611  WAUZZZ4L3AD029002

A8

On the V6 engines the pipe processing was changed from the following engine numbers:
No damage is known on improved engines.

file:///D:/ElsaWin/docs/hs2/A/en-GB/src/01/707073/master.htm

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V6/V8/V10 FSI, metallic knocking noises from engine compartment(2015932/15)

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V6 engines
AUK no longer in production, improved for Parts.

Audi A4/S4

V6

BKH 082367      WAUDH48H59K008671
CALA 002310  in A5  WAUZZZ8T29A030735
CALA 027346 in A4   WAUMK78K69N043216
AUK no longer in production, latest version in parts system.

Audi A6

V6

BKH 087437     WAUCH74F09N028388
CAJA 001625   from start of production
CCE 007769     improved for replacement parts

Audi A8/S8

V6

BPK 013219     WAUZZZ4E09N011410

V6

BDX 020858     WAUKH54E99N010432

Measure
Try to reproduce the customer complaint  so that it can be clearly assigned to this TPI. Perform the
following repair only, if all criteria match exactly. Otherwise this solution won't work and repeat repairs
may be necessary. In such a case, we may reject the warranty claim and redebit the parts.
For a safe diagnosis inspect the running surfaces of the cylinder with an endoscope. A safe sign are
light, metallic blank, polished-looking areas in the endoscope, mainly near the upper or lower dead
centre (marked red in the photos). On improved engines, as in the above photos, no cylinder pipe
damage is possible.
The rubbed off aluminium can be found as a thin layer of fine, grey sludge on the bottom of the oil
sump. For a further confirmation take off the oil sump. Rubbing lightly on the surface of the oil sump
causes smears, see photos.

file:///D:/ElsaWin/docs/hs2/A/en-GB/src/01/707073/master.htm

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The rubbed off aluminium can be found as a thin layer of fine, grey sludge on the bottom of the oil
sump. For a further confirmation take off the oil sump. Rubbing lightly on the surface of the oil sump
causes smears, see photos.

file:///D:/ElsaWin/docs/hs2/A/en-GB/src/01/707073/master.htm

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If all three symptoms, knocking noise, blank areas and aluminium abrasion in the oil sump, are
present, damage to the cylinder running surfaces is highly likely. Proceed as follows:.
1.

Replace the short engine (cylinder block with piston or short engine depending on availability).
The replacement of the cylinder heads is not necessary, as only cylinder surfaces are
damaged. The cylinder heads are not damaged.

2.

Replace the oil filter and the engine oil.

3.

Run the engine for 30 minutes at 2000 rpm to flush the engine oil system.

4.

Fit another new oil filter, drain the engine oil and refill the engine with fresh oil.

5.

Account under service number 1009.

Warranty accounting instructions
Accounting with APOS:
1.
Repair operation:

28 70 20 xx

Designation:
Remove and install spark plugs

Time units:
According to
APOS

10 09 02 99

Endoscope running surfaces of cylinders (cyl.
4 - 6)

20 TU

10 09 02 99

Endoscope running surfaces of cylinders (cyl.
8 - 12)

40 TU

17 50 19 xx

Remove and install oil sump

According to
APOS

10 01 19 xx

Remove and install engine

According to
APOS

10 03 33 xx

Complete short engine

According to
APOS

10 02 33 xx

Complete short engine

According to
APOS

01 04 00 xx

Oil change service

According to
APOS

The labour times are correct at the time of publication.
Accounting with APOS/2:
Illustration:

Position:

Number:

Designation:

file:///D:/ElsaWin/docs/hs2/A/en-GB/src/01/707073/master.htm

Activity:

Time units:

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V6/V8/V10 FSI, metallic knocking noises from engine compartment(2015932/15)

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905-xx

2

905611

Replace spark plugs

19

According to
instructions

103-xx

1

103011

Endoscope running
surfaces of cylinders (cyl.
4 - 6)

01

20 TU

103-xx

1

103011

Endoscope running
surfaces of cylinders (cyl.
8 - 12)

01

40 TU

103-xx

19

103603

Remove and install oil
sump

19

According to
instructions

100-xx

2

P01003

Replace short engine

55

According to
instructions

100-xx

1

P01002

Replace engine with short
engine

55

According to
instructions

IWV-xx

21

F10000

Change oil/oil filter

55

According to
instructions

The labour times are correct at the time of publication.

Customer information
---

file:///D:/ElsaWin/docs/hs2/A/en-GB/src/01/707073/master.htm

12/05/2015



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