2004 Audi S4: engine failure

Filed Oct 24, 2017 · Engine · 102,000 miles · NJ

After engine cools down, timing chain rattle can be heard upon starting the car. Chain rattle means that plastic guides or adjusters are worn, and might go any second. Spoke with audi rep online, which advises me that this is normal, and expected. Knowing basics of engines and transmission, I didn't believe that something is "life time" and is not serviceable, especially if it's plastic (which tends to shrink and expand depending on temperatures, and then has fractures which snaps). Two different independent licensed audi shops confirmed that the guides and adjusters has to be replaced in order to prevent catastrophic engine failure. Chain skipping a tooth might mean bent valves, scored cylinder walls and the list goes on. What is lifetime, should be covered by audi. If it's promised to be lifetime and needs no service, shouldn't break. If it breaks that only means design flaws, which are obvious in this engine. Yes, car isn't new, but the parts were lifetime, so I'm expecting them to last until engine is worn out, not the parts that are lifetime. If the federal safety agency will do full scale investigation. Will be obvious that large amount of s4's ranging from 2004 to 2007 are affected. Even 10% is large number, considered the costs of fixing what is "lifetime" according to audi, and when it fails they leave their designs flaws for you to figure out. Hopefully justice can be brought to light as to what audi tries to turn it's back to. Symptoms: chain rattle upon start. Chain rattle doesn't go away while driving. Check engine light, loss of power or catastrophic engine failure.

Filed Aug 14, 2014 · Engine, Transmission · 80,000 miles · CT

Audi claims that the timing chain on those vehicles are lifetime and does not need to be service. Unfortunate the timing change tensioners are made of plastic which the wear out at about 50k miles, causing a start up rattle and eventually engine explosion from the chain coming of the guides and destroying the entire engine and causing a massive accident at high speed. Hundreds of problems like this one are reported online from thousands of people even youtube videos. Not to mention that every time you bring your vehicle and complaint to audi the claim that the rattle is normal; just to find out that is the first clue of future engine failure.

Filed Feb 2, 2012 · Engine · CA

2004 audi s4. Consumer states vehicle failed while driving, engine, power brakes and steering locked up *tgw the dealer informed the consumer, the vehicle had suffered catastrophic engine failure, which was most likely due to the failure of the timing chain or adjusters. The consumer was quoted a price of $24,000 for the repairs. The consumer has since learned it was a relatively common problem for his model and year. The specific mechanical flaw seemed to be that the timing chain coordinated the action between the pistons and the valves. The timing chain was supported by several plastic guides. The guides pushed against the chain by the adjusters.

Filed Jan 13, 2012 · Transmission · 55,000 miles · IN

I own a 2004, audi, s4 which I purchased used from my brother, who bought it new. I bought this car from him with 45,000 miles on it. At 55,000 miles the car had catastrophic engine failure. 5,000 miles over the warranty period! The mechanic that is repairing the damage said if one more component would have broke it could have caused me to lose control of the vehicle and crash. The engine and transmission had to be removed from the vehicle to be repaired. I contacted audi of u.s.a. To,1. Alert them of this problem and possible safety issue, 2. Because the car is only 5,000 miles over the warranty and it had such massive failure I believe it only reasonable to ask for some help in the cost of repairs. The repair cost are going to be between 4,000 and 5,000 dollars. 3. I work in quality assurance for a company and I really wanted to speak with their quality assurance and alert them to this big problem. It is crucial they (audi) understand the problem. The reps at audi of u.s.a. That I spoke with would not help (except to listen, they are good at that), and were not cooperating with me in the process of trying desperately to alert their quality people of this failure that occurred to my car. I believe I was completely ignored and I need to find out how I can effectively report this. Not only to audi but also other people who own the same vehicle. This is a major issue that needs to be made public. Thank you.

Filed Jan 3, 2010 · Engine · 103,000 miles · WI

Engine failure going 45mph due to broken valve spring. Faulty part documented in 5/2005 USA today but audi will not repair.

Filed Dec 9, 2009 · Engine · 94,000 miles · WI

Car engine was misfiring - was informed a faulty coil pack was causing the issue. One week later the misfires started again. Two more coil packs were replaced. 2 weeks later another misfiring episode. Car died at intersection so was towed in for inspection. Camshaft adjuster/cam guides had failed. Parts were replaced for 5k and then 2 weeks later cylinder 3 failed when valve and piston interacted - car died again on the highway. Car engine is going to need total engine replacement.

Filed Dec 7, 2009 · Engine · 54,000 miles · MD

See the federal safety agency odi complaints: 10267048, 10263937, 10262201, 10261864, and 10261281 my first experience with the catastrophic engine failure of the "cam chain tensioner" components was in dec of 2008 on the bank 2 cam. Fault code "set point not reached (over-retarded)." with misfires to all cylinders on bank 2 - all but rendering the vehicle unable to drive. There was approximately 54,000 miles on the odometer. Though out of warranty I contacted audi to no avail. I am sorely disappointed in audi for engineering such shoddy design, and not standing by their product. In fact criswell audi charged $300 for an ecu update that did nothing. Although the s4 is a low volume car the 4.2l engine is used in many of their products; and if this complaint venue any indication it appears to suffer a high percentage of expensive and dangerous failures. The cost to drop the engine and transmission in order to make the repair was ~$4,500.

Filed Dec 7, 2009 · Engine · 70,000 miles · MD

See the federal safety agency odi complaints: 10267048, 10263937, 10262201, 10261864, 10261281, and 10294798. My second experience with the catastrophic engine failure of the "cam chain tensioner" components was in nov of 2009 on the bank 1 cam. Fault code "set point not reached (over-retarded)." with misfires to all cylinders on bank 1 - less than one year from the same failure on bank 2 (see the federal safety agency odi complaint #10294798). There was approximately 70,000 miles on the odometer. As I mentioned before, although the s4 is a low volume car the 4.2l engine is used in many of their products; and if this complaint venue any indication the engine appears to suffer a high percentage of expensive and dangerous failures. The cost to drop the engine and transmission in order to make the repair was another ~$4,500.

Filed Apr 2, 2009 · Engine · 34,000 miles · AL

Catastrophic engine failure and seize at 70mph. Previous the failure, audi replaced bent valves due to timing chain tensioner failure. Less than 300 miles from new heads being installed, the engine failed completely.