2.0l tfsi bpg cylinder head failure (56k warning)

[09etech]

CUSTOMER STATED CAR DIED AT LIGHT LIKE IT RAN OUT OF GAS, THOUGHT IT WAS THE POWER OUTPUT STAGE FUSE BLOWN BECAUSE OF SHORTED COIL, FUSE OKAY AND NO FAULTS THEN REMOVED OIL FILL CAP AND HAD SOMEONE CRANK WHILE I WATCHED THE VALVETRAIN AND FOUND INTAKE CAM NOT TURNING UHH OH, FOUND THIS AFTER REMOVING VALVE COVER AND CAMS




http://i48.tinypic.com/71tv5x.jpg
http://i46.tinypic.com/25rie5s.jpg
http://i48.tinypic.com/rlazom.jpg

INTAKE CAM HYDRAULIC ADJUSTER BOLT BROKEN OFF IN EXHAUST CAM
http://i49.tinypic.com/zj9ssy.jpg
http://i45.tinypic.com/307usko.jpg
http://i47.tinypic.com/sxk76t.jpg
http://i48.tinypic.com/amt9ax.jpg

http://i47.tinypic.com/2emq7hz.jpg

REMOVED INTAKE MANIFOLD PREPARING FOR HEAD REMOVAL DECIDED TO SHOW HOW SHITTY THE VALVES LOOK

http://i48.tinypic.com/o9fuxs.jpg

REMOVED OIL PAN TO LOOK FOR LITTLE STRAGGLERS

http://i49.tinypic.com/3343srs.jpg

LEFTOVER PIECES FROM THE TENSIONER SHOE

http://i46.tinypic.com/214v1vl.jpg

READY TO REMOVE BALANCE SHAFT MODULE WITH OIL PUMP TO CHECK CON-ROD BEARINGS AND MAINS FOR SIMILAR WEAR AS CYL HEAD

http://i46.tinypic.com/hskdc9.jpg
http://i46.tinypic.com/fw2kk4.jpg

AND NOW OUT

http://i45.tinypic.com/pbt6o.jpg
http://i47.tinypic.com/207pahj.jpg
http://i48.tinypic.com/2zhdssk.jpg

http://i45.tinypic.com/103gxl1.jpg



AND LOOK AT THE VARIETY OF BOLTS IT COMES WITH S#!T!!!! [wrench]
SEVEN DIFF SIZES, *NOTE* DON'T MIX THESE UP [confused]


http://i46.tinypic.com/2affrxj.jpg
http://i49.tinypic.com/25txk7r.jpg
http://i50.tinypic.com/20jr1uu.jpg




GONNA POST FINDINGS ABOUT BOTTOM HALF TOMORROW
STAY TUNED

[jayphil82]

Outch!

What is the model year of this car? What was the milage on the engine?

[champion]

Don't be surprised, almost all of the fsi heads look this way due to the fuel being directly injected and nothing to clean out the ports or valves. As for the journals that are hammered, thats a whole other problem. AND WHY THE HELL IS THE GUY USING REGULAR OIL[headbang]

[VODeftones]

2nd on the shitty maintenance of that vehicle, I've seen 1.8t lock up the cams and in the head and shear off the cam gear but not on a 2.0t yet because they always had synthetic oil, unless you have shit for brains and ran organic

[doctorheine]

wow ... is this the person that also uses 87 instead of 93

[Sales@RAI]

nice carnage pics

[09etech]

Connection offline
Technical Service Bulletin Transaction No.: 2021232/4
01 MIL on (DTCs for misfire, P0300 - P0312) Release date: Mar 24, 2010


• This TSB is for interim claims for 28F2/J1 campaign vehicles only. Applicable vehicles must fall within VIN ranges noted in this TSB. 2.8L engines are not affected in this scope. Coils of screw-down design (non “pencil” type) are also not affected.

• The MIL is flashing or constantly illuminated.

• DTCs for misfire in one or more cylinders (P0300 to P0312, depending on the engine) are stored in the ECM data memory.


Technical Background

The misfire condition can be caused by an inoperative ignition coil.

• 2.8L engines are not affected in this scope.

• Screw-down design (non “pencil” type) coils are also not affected.

• The following VIN ranges are affected by this condition:

Model Year 5th Digit of VIN VIN Range

TT 01 C 000888 – 007031

TT 01 X 010017 – 049102

TT 02 C 000168 – 042277

TT 02 X 005133 – 009900

TT 03 C 000233 – 024032

TT 03 T 000222 – 024025

TT 04 C 000558 – 029928

TT 04 F 007023 – 030002

TT 04 T 000349 – 029716

TT 05 C 000117 – 017177

TT 05 D 012805 – 017362

TT 05 F 000116 – 012682

TT 05 T 000448 – 017389

TT 06 C 000128 – 010508

TT 06 D 000120 – 010509

TT 06 T 000184 – 010490

A3 06 D 061021 – 220863

A3 06 F 000150 – 220843

A3 07 D 000226 – 098726

A3 07 F 000229 – 153553

A4 01 C 000165 – 156553

A4 02 C 000003 – 000003

A4 02 C 014319 – 314607

A4 02 T 053704 – 314599

A4 03 C 098522 – 407119

A4 03 T 100031 – 406848

A4 04 C 000626 – 303744

A4 04 L 000608 – 303627

A4 04 T 000669 – 303612

A4 05 C 000595 – 126142

A4 05 F 405683 – 579570

A4 05 G 409266 – 579567

A4 05 L 000614 – 579574

A4 05 T 000571 – 126039

A4 06 F 000252 – 298020

A4 06 G 000253 – 097977

A4 06 H 098173 – 297198


First 3 of VIN: WUA

A4 06 L 700001 – 700250


First 3 of VIN: WAU
4 06 L 000893 – 297822

A4 07 F 000566 – 190045

A4 07 H 000569 – 189834



First 3 of VIN: WUA

A4 07 U 900005 – 905810

A4 Cabriolet 03 C 012363 – 033851

A4 Cabriolet 03 T 003474 – 033839

A4 Cabriolet 04 C 000203 – 029135

A4 Cabriolet 04 L 900036 – 901732

A4 Cabriolet 04 T 000377 – 029211

A4 Cabriolet 05 C 000155 – 025738

A4 Cabriolet 05 L 900002 – 902715

A4 Cabriolet 05 T 000150 – 025666

A4 Cabriolet 06 C 000131 – 011887

A4 Cabriolet 06 L 900007 – 900851

A4 Cabriolet 06 T 000118 – 011890

A4 Cabriolet 07 F 013458 – 027616

A4 Cabriolet 07 H 013759 – 027614

A6 / allroad 02 T 005022 – 152647



First 3 of VIN: WAU
A6 / allroad 03 D 000589 – 116152


First 3 of VIN: WA1
A6 / allroad 03 D 000602 – 115020
A6 / allroad 03 T 000584 – 116100



First 3 of VIN: WAU
A6 / allroad 04 D 000386 – 104181



First 3 of VIN: WA1
A6 / allroad 04 D 000394 – 103175



First 3 of VIN: WA1
A6 / allroad 04 L 000265 – 102043
A6 / allroad 04 T 000734 – 104386


First 3 of VIN: WA1

Allroad 05 D 000168 – 027457




First 3 of VIN: WA1
A6 / allroad (C5) 05 L 000167 – 027295

A6 05 G 051555 – 125122

A6 05 L 019038 – 125126

A6 05 T 035977 – 055794

A6 06 G 015585 – 075340

A6 06 H 074370 – 195078

A6 06 L 020313 – 191225

A6 07 H 002048 – 113889

A6 07 N 023125 – 111877

A6 07 V 002253 – 113577

A8 04 L 000392 – 026440

A8 05 L 000442 – 017205

A8 05 R 008681 – 017118

A8 06 L 003536 – 026798

A8 06 R 003913 – 026563

A8 07 N 004243 – 014713

A8 07 V 000292 – 014930

Q7 07 V 001257 – 080132

Q7 07 Y 019586 – 080218




Production Solution

Vehicles out of production.

Service

It is not necessary to perform the complete Guided Fault Finding with the VAS tester.

1. Check for Campaign Completion Label

Verify whether a Campaign Completion Label using SAGA Code 28F2 is affixed next to the vehicle emission control information label.

If the Campaign Completion Label using SAGA Code 28F2 is present, do not proceed with this TSB.


2. Address misfire DTCs stored in the ECM data memory

Replace ignition coils (including cylinders without a misfire DTC) as listed in the following table. Not all coils may require replacement. (See matrix below for details.)


Note:

To prevent damage, please use appropriate tools to remove coils (such as coil puller tool T40039). Do not twist ignition coil when installing. Do not use any object to tap the ignition coil into position. Please be careful not to break the electrical connector.

A. GOOD PARTS: If the following part numbers are found, leave in car
B. If coil in car is not listed in column A., replace with:



ENGINE ENGINE CODE A. GOOD PARTS: B. REPLACE WITH:
If the following part numbers are found, leave in car If coil in car is not listed in column A., replace with:

1.8T AWM 06B 905 115 R 06A 905 115 D
2.7T AMB 06C 905 115 L
AWP 06C 905 115 M
BEA
BEL





2.0T FSI BPG 07K 905 715 D/E/F 06H 905 115
BWT 06H 905 115
BPY 06F 905 115 F
06D 905 115 K
06E 905 115 D/E




3.0L AVK 06A 905 115 D
BGN 06C 905 115 L 06C 905 115 M
06B 905 115 R






3.2L SRE (VR-6) BHK 022 905 715 022 905 715 B
3.6L FSI BHE
BUB





5.2L FSI BKH 06E 905 115 D/E 06E 905 115 E
3.2L FSI BVJ 07K 905 715 D/E/F
4.2L FSI (except RS4) BAR 06D 905 115 K
BXA 06H 905 115
BSM 06F 905 115 F






4.2L (non-FSI) BFM 077 905 115 Q 077 905 115 T
BGK 077 905 115 S
BAS
BNK
BHF







4.2L FSI RS4 only BNS 07K 905 715 D 07K 905 715 F
06H 905 115
06F 905 115 F
06D 905 115 K
06E 905 115 D/E







6.0L BSB 07C 905 115 J 07C 905 715 A



3. Complete the Campaign Completion Label

In the United States and Canada, vehicles repaired under the 28F2 emissions campaign (or this interim TSB) are required to be identified with a Campaign Completion Label.



Figure 1. The Campaign Completion label.



1.
Order labels at no cost from Archway Marketing Services (formerly Resolve Corporation) at 1-800-544-8021. The part number is CAMP 010 000.

2.
Fill out the Campaign Completion Label using SAGA Code 28F2.

3.
Ensure the area next to the vehicle emission control label is clean.

4.
Affix the Campaign Completion label next to the vehicle emission control label.



4. If other DTCs are also stored in the ECM data memory, or if the misfire condition is not corrected by the replacement of the ignition coils:

Diagnose the condition and perform necessary repairs with the use of Guided Fault Finding, the Repair Manual and applicable Technical Service Bulletins.

Tip: These additional repairs are not covered by this Technical Service Bulletin.

5. In the state of California only:

The California Air Resources Board and the Department of Motor Vehicles (DMV) require emissions-related campaigns to be completed prior to vehicle registration renewal.

1. When campaign work is done, provide the owner with a signed “Vehicle Emission Recall – Proof of Correction certificate (RC EMISCAVWAU).

Certificates can be ordered at no cost from Archway Marketing Services (formerly Resolve Corporation) at 1-800-544-8021.

2. Ensure owners are aware of the importance of retaining the completed certificate for their records. The certificate should be mailed to the California DMV only upon request.


Warranty

• It is still possible to claim this TSB for vehicles outside of the Limited New Vehicle Warranty.

• Submit only one warranty claim per case.

• The removed parts remain at the dealer and must be destroyed, not reused.

• The destroyed parts must be kept for inspection at the dealer for 20 days after the payment of the warranty claim.

• Put the parts label on all the removed parts you store (allocation of the parts in case of warranty audit or subsequent request by the manufacturer).


Claim Type:
Sold Vehicle = 7 10 OR unsold vehicle = 7 90

Service Number:
28F0

Damage Code:
0099

Criteria ID:
99

Labor Operations:
Ignition coil replacement
2820 2099
Refer to Labor Operation Time Unit Matrix below

Outside Material (Towing)
Towing only applies to vehicles outside “Roadside Coverage.” Reason for towing must directly relate to this TSB. Enter the word “TOW” as the Description; enter “1” under Quantity; select “ea” under Unit. (Ensure loaner sales receipt is attached to repair order.)
Not to exceed $100

Diagnostic Time:
GFF - Read and delete ECM data memory
0150 0000
10 TU

Road test prior to service procedure
No allowance
0 TU

Road test after service procedure
No allowance
0 TU

Technical diagnosis
No allowance
0 TU

Claim Comment:
As per TSB #2021232/4



Labor Operation Time Unit Matrix:

Engine Vehicle Time Units

1.8T A4
A4 Cabriolet 40TU

TT 50TU



2.0T A3 40TU
A4
A4 Cabriolet



2.7T A6 130TU
Allroad


3.0L A6 90TU
A4
A4 Cabriolet

3.2L A4 70TU
A4 Cabriolet
A6
70


A3 50TU
TT 50TU


3.6L Q7 50TU

4.2L Allroad 110TU
RS4 (MY 2007)
S4
S4 Cabriolet

Q7 70TU
A6 (MY 2007) 70TU

A6 (MY 2005-2006) 90TU
A8 90TU

5.2L S6 130TU
S8

6.0L A8 160TU


All warranty claims submitted for payment must be in accordance with the Audi Warranty Policies and Procedures Manual. Claims are subject to review or audit by Audi Warranty.

All part and service references provided in this TSB are subject to change and/or removal. Always check with your Parts Dept. and service manuals for the latest information.

©2010 Audi of America, Inc. All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of Audi of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.

[drumnjuny]

sorry y'all, bringing this thread back to life. most likely the same situation me and IRATI are in right now. looks like OP never came back to this thread or forum but hey worth a shot right

[Operator]

Have you tried, emailing him via his profile page? Or shooting him a pm (he might get an email notification), also sending a friend invite, might get his attention.