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A collection of challenging repairs on European models

Tuesday, August 30, 2016 - 07:00
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Our first vehicle is a 2006 Audi A4 2.0L Turbo (Figure 1) that was towed in for a no start concern. The young guy that was driving the vehicle stated that the vehicle had been losing power and smoking from the tail pipe before it shut down and no longer started. Our next step after the owner interview was a visual inspection that revealed a motor that was down a quart of oil and looked like no maintenance had been done for a while. The visual was followed by a scan of the computer system revealing a P2293 (Fuel Pressure Regulator 2 Performance), P1093 (Fuel Trim 2, Bank 1 Malfunction), P0300 (Random Cylinder Misfire), P301, P302, P303 and P0304  (Cylinders 1 – 4 Misfire) DTCs.

Figure 1

Checking our service information system, we found a Technical Service Bulletin (TSB) No. 2013147/1 that detailed a problem with the camshaft, camshaft follower and fuel pump. Armed with the TSB information, we decided to call the local dealer and provided them with the VIN number to see if the vehicle was eligible for the warranty repair. Unfortunately for the vehicle owner, his vehicle was not eligible for the repair since the car was over the 10-, 120,000-mile limitation. Now the vehicle owner was on the hook for the repairs that needed to be performed.

We called the owner and requested additional time to check fuel pressure and for the labor necessary to remove the fuel pump so that we could visually check the cam follower, fuel pump and camshaft for damage. The fuel pressure test was not conclusive since it tested only the low pressure side (the delivery from the fuel tank to the low pressure side of the high pressure fuel pump). Because there was no way for us to test the high pressure side of the pump, we had to remove the fuel pump and visually inspect the cam follower (Figure 2). Take a look at the worn one verses the new one. The camshaft was also damaged (Figure 3) along with the tip of the high pressure fuel pump.

Figure 2
Figure 3

During our visual inspection we had noticed an oil change sticker from a tire shop that advertises a $19.95 oil and filter change. We have seen a variety of engine problems over the years caused by improper oil changes using the wrong type of oil and suspected the same here. As most of you know, you cannot purchase the correct oil and filter for $19.95 for an Audi, let alone perform the service for that price. With that information at hand, we thought that we better do a bit more digging into to the engine before providing the owner with a price for the to repairs.

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