Valve cover failure? Oil consumption and lots of smoke, maybe on to something.

[Xlimited]

Hello everyone! I apologize about the long post ahead of time. I got a 07 Audi A4 2.0T with 74,000 miles. I've owned the car for about 1500 miles. The car starts and idles fine. I can pass cars with no problems, drives down the road fine. I live in a very rural two lane highway area. No expresseway driving. I have this one big hill that I have to go up and its from a dead stop and it's a 50 mph road so the car gets a pretty decent load to get up to speed hangs around 4 grand for awhile.( I guess I could compare this to coming onto a on ramp and getting up to expressway speed). Every time I get over half way up the hill I get a massive James Bond smoke screen of blueish white smoke. At the same time it seems like the car is struggling also wants to misfire due to the massive amount of oil getting in to combustion chamber maybe? One time it did misfire enough for me to pull over threw a check engine light for cylinder three misfire, it was definitely running on three cylinders. After a minute of light to medium revs in park and messing with swapping coil packs to different cylinders didn't change which cylinder my misfire was on. It cleared up and drove home fine like the plug was loaded up. If I just run the car hard like a 0-60 I might get a little blue at the top of the rpm band but not much at all or a hard couple car pass I don't get the smoke, only time I can get it to do it is on that hill.
I've done some research and the oil is not milky and my coolant level hasn't changed but I do go through oil. I don't think it's the turbo and I blew into the intake tube of the pvc and it wouldn't let air in but there was oil residue in the tube.

I've came across this post on another forum board. Here is the link read the original poster and then skip down to post 26 and 29. The rest of the posts are stuff that's been gone over a million times
http://www.audiworld.com/forums/a4-b...2825288/page3/

Then I found this link on this forum board that explains the valve cover failure. It's a good explanation of the failure and discussion.
http://www.audizine.com/forum/showth...-oil-separator

I've got a second 06 Audi A4 that I picked up with a bad engine and am in the process of swapping engines in at the moment and that bad engine has the silver valve cover compared to my 07 black valve cover, the new engine I'm putting in that car also has the black valve cover, by reading that second link it seems like the silver ones were holding up better? I've inspected it very closely and haven't found any cracks or loose parts on that silver valve cover. Also previous owner of the 06 Audi said he never had any oil consumption issues. I work all weekend and won't have time until next Tuesday to swap out the valve covers and take it for a test drive up the dreaded smoke screen hill. I might just be wasting my time and it could just be rings or turbo or who knows what. . Just looking for opinions and advice. Also will the silver valve cover came on a bpg engine and the black ones are on a bwt engine, will they swap out or are they different? Thanks for reading my long ass post and I hope to have some results by next week.

[RickB_7]

Before Charles says something. I'd say definitely worth looking into that valve cover. Your problem sounds eerily similar to mine, I had a hill I went up not far from my house that I could "floor it" up and make a big cloud (though I'd describe it as black smoke). One other time going over a mountain pass (miles of up hill) my car misfired so bad I had to pull to the side of the road due to the loss of power. Long story short, in my experience yes it sounds like a valve cover issue I'd pull it off and take a look

the crack on the underside of my valve cover

[Low and Behold]

Agreed with Rick. Check the VC.

The crack Rick is showing above is exactly what happened to mine as well. Mine was also right up against the PCV. Basically an open path for oil to get sucked straight through into the turbo/intercoolers and then sucked back through your intake. Not good.

Also for reference, the silver VCs are the early ones, the black VCs are the "updated" ones. Same design

Heres a link to a thread I had with similar issues http://www.audizine.com/forum/showth...il-Consumption

For the record, changing the VC did fix my consumption. But now I'm chasing a fueling issue

[Xlimited]

Awesome news to hear, I do at times get black smoke going up the hill or passing but not enough to worry about compared to the huge cloud I'm getting going up the hill. I'm hoping to find the same crack you guys have found. I went to a local performance place and he was telling me my turbo was bad. It looks like in the picture the crack is not very noticeable.

[Low and Behold]

Shop told me my turbo was bad too. Replaced it to no avail. Who knows? Yours could be bad but theres plenty to check beforehand

A telltale sign of a crack in the VC for me was this:



Excessive oil making it through the PCV breather into the turbo inlet. Maybe take a peek at that, since you just need to pull the turbo inlet pipe. Super easy to check. I also had a TON of oil in my intercooler piping.

[Xlimited]

Yeah the guy really didn't seem to want to look at my car or give it a 100% effort so I'm saying that's his half ass guess. Are you talking about that port with the metal loom with the oil collecting at the bottom? Which intercooler piping had all the oil? The passenger side one? I'm assuming it was the lower one you removed to find all the oil?

[Low and Behold]

Are you talking about that port with the metal loom with the oil collecting at the bottom? Which intercooler piping had all the oil? The passenger side one? I'm assuming it was the lower one you removed to find all the oil?

Yes, and both lower IC hoses had oil

[Xlimited]

Update, I replaced the valve cover out of the other engine that has the silver valve cover and the James Bond smoke cloud is gone. I have the same separation crack has the pic above. Also had the same oil collecting in the turbo inlet (metal loom pipe). Removed both lower intercooler pipes and there was a solid two cups of oil between the two. I'm ordering a new valve cover because I feel like the used one I put in there isn't too far behind the other one. If any one has any oil consumption it's an easy check to see if it's the valve cover. Remove the pipe from air box to turbo and if you see oil in that port your valve cover is most likely bad.

[KJack]

Good to hear. I'm glad you didn't listen to the local performance shop!

[brandonpham]

I wish this was my issue. My intercooler pipes have been so dry lol.

[Charles.waite]

Before Charles says something.

Hahah, Touché!

But yea check the IC pipes for oil, and check the valve cover passage seals and plug holes for oil leaking. FWIW, my turbo has trace oil like in that picture above, and replacing the VC and PCV did nothing for that or the consumption. Small amounts of oil in the intake tract is unavoidable on a journal bearing turbo car (and the 2.0t more so than most others), but my "some oil" I mean an ounce or two. If you've got more than that coming out then you've got some serious leakage that should be addressed.

Glad that other VC solved your problem though! For sure pickup a new one. GenuineAudiParts.com generally has the best pricing on OEM parts, but their ordering system is a bit funky.

[brandonpham]

Hahah, Touché!

But yea check the IC pipes for oil, and check the valve cover passage seals and plug holes for oil leaking. FWIW, my turbo has trace oil like in that picture above, and replacing the VC and PCV did nothing for that or the consumption. Small amounts of oil in the intake tract is unavoidable on a journal bearing turbo car (and the 2.0t more so than most others), but my "some oil" I mean an ounce or two. If you've got more than that coming out then you've got some serious leakage that should be addressed.

Glad that other VC solved your problem though! For sure pickup a new one. GenuineAudiParts.com generally has the best pricing on OEM parts, but their ordering system is a bit funky.

I forget, have you solved your issue yet?

[Charles.waite]

I forget, have you solved your issue yet?

Nope. Work and family have all conspired to backburner the issue for now. I had a rebuilt turbo ready to go but ended up selling it to a buddy whose turbo blew.

At some point I'll have the issue licked but I plan on doing a bottom end rebuild and new rings. My main problem is time right now. I almost never drive my car now so in that sense it's the perfect time to pull the engine, but I have nowhere to do it and no time to mess with it. And now with the weather turning I'm even less inclined to deal with it.

I'm also kinda sorta waiting for Tankdeer to do his 2.7t swap so I can swoop in on their engine and just swap this lemony ass engine out. And then maybe rebuild it and sell it or who knows....

[brandonpham]

Nope. Work and family have all conspired to backburner the issue for now. I had a rebuilt turbo ready to go but ended up selling it to a buddy whose turbo blew.

At some point I'll have the issue licked but I plan on doing a bottom end rebuild and new rings. My main problem is time right now. I almost never drive my car now so in that sense it's the perfect time to pull the engine, but I have nowhere to do it and no time to mess with it. And now with the weather turning I'm even less inclined to deal with it.

I'm also kinda sorta waiting for Tankdeer to do his 2.7t swap so I can swoop in on their engine and just swap this lemony ass engine out. And then maybe rebuild it and sell it or who knows....

I wish I was in that position. I drive my 350Z all the time now since my only passengers are the girlfriend or my Doge. Winter is coming so I can't risk a tear down that will take longer. Buying a motor can be costly vs the $20 5 qt jug of Rotella T6 I buy every few weeks lol.

I also saw that discussion about the 2.7t and I'm thinking about it more, but I need to keep it daily drivable. They pop up around my area for so cheap!

[Okedokey]

Rule #22.

[Charles.waite]

Rule #22.

Since you did not specify...

[brandonpham]

Since you didn't specify... here's my lady doge.

such internet much shibe wow

[Charles.waite]

I wish I was in that position. I drive my 350Z all the time now since my only passengers are the girlfriend or my Doge. Winter is coming so I can't risk a tear down that will take longer. Buying a motor can be costly vs the $20 5 qt jug of Rotella T6 I buy every few weeks lol.

I also saw that discussion about the 2.7t and I'm thinking about it more, but I need to keep it daily drivable. They pop up around my area for so cheap!

I drive maybe 20 miles a week right now. Free bus pass from work + carpooling with the SO, means the b7 languishes in front of the house and only gets driven on grocery runs really. I haven't had to fill up the gas tank since mid August, haha!

But yea I have no garage and so no place at home that's clean enough so that I could rebuild an engine in a reasonable amount of time. And just tossing a quart of oil in every now and again has worked out fine for the past 3 years so in my mind there's no real rush.

[brandonpham]

I drive maybe 20 miles a week right now. Free bus pass from work + carpooling with the SO, means the b7 languishes in front of the house and only gets driven on grocery runs really. I haven't had to fill up the gas tank since mid August, haha!

But yea I have no garage and so no place at home that's clean enough so that I could rebuild an engine in a reasonable amount of time. And just tossing a quart of oil in every now and again has worked out fine for the past 3 years so in my mind there's no real rush.

I feel the same, but have you tuned yet? I really just wanna go JHM S1 already. I'm sure it won't make the oil consumption worse, but it could lead to other items. I got nothing on my mod list coming up but installing the suspension and spacers I bought lol.

[Charles.waite]

I feel the same, but have you tuned yet? I really just wanna go JHM S1 already. I'm sure it won't make the oil consumption worse, but it could lead to other items. I got nothing on my mod list coming up but installing the suspension and spacers I bought lol.

Nope still stock now. I for sure want to tune it but I want to wait until I'm more financially ready for the possibility of the engine going south. Normally I wouldn't ever consider a tune to cause too much stress on the engine but I just really don't trust my engine all that much and adding more stress and pressure to it just doesn't fill me with a warm and fuzzy feeling so much as a dread of what might fail.

[brandonpham]

Nope still stock now. I for sure want to tune it but I want to wait until I'm more financially ready for the possibility of the engine going south. Normally I wouldn't ever consider a tune to cause too much stress on the engine but I just really don't trust my engine all that much and adding more stress and pressure to it just doesn't fill me with a warm and fuzzy feeling so much as a dread of what might fail.

Makes me happy to know someone feels the way I do. My car has never had any serious problem aside from consumption, the coolant flange that went, and the one time my thermostat went, but all it did was cause my temp to go down while coasting. Its happily reliable right now and I agree about being financially ready for a major motor situation.