[s-cars] Further Developments -- 94 S4

Mon Mar 5 14:49:18 PST 2012

From: Keith Franchetti <skidfranc at gmail.com>
Date: Mon, Mar 5, 2012 at 5:35 PM
Subject: Re: Further Developments -- 94 S4
To: b1biker at aol.com

Hey Gary-

If your threads on the head are shot and plug is loose, you certainly seem
to need the TimeSert repair.  A few recommended helicoil instead, but if
you read up on the two repairs at all, it's clear Time Sert is the better,
more permanent repair.  TimeSert even has a special tool/insert for failed
helicoil repairs.  The TimeSert tool cost me $180.  I'd be happy to pass it
along to you for $120, if you'd like.  Really well-made tool.  I certainly
hope and expect never to need it again.  If you haven't already checked out
the company site, here is a link to the video of how to do the repair.
http://www.timesert.com/html/howtosp.html  Several people on the list
cautioned me strongly against doing this job myself.  You are cutting a
bigger hole in your cylinder head, afterall.  Mess up and you have a very
expensive paperweight, I was told.  But it was as easy to do as the video
makes it look.  And I didn't think I was going to find anyone who cared as
much as me about doing it carefully and well. Going very slowly and
deliberately, in the rain no less, it took less than an hour.  But if you
don't feel confident, I'd look into having someone who really knows their
stuff (and cares about your car as much as you do) do it for you.  Anyway,
so let me know if you want to buy my tool.  Either you or I would also have
to order the actual insert, which threads into your new hole, and becomes,
itself, the new spark hole.  Have to look up the exact right size for you
if you want to order it.  It's only like $3 on Amanzon!

As for the oil, if it's all down in your spark plug wells, I don't see
where besides the valve cover gasket that could be coming from.  Has got to
be a gasket failure, I believe.  And if the valve cover gasket is in fact
shot--probably catastrophically after the plug mishap, and you'll see why
as you are replacing it!--that would be letting a LOT of oil out.  Might
START under the coil cover, and spray out from under that plate (that was
happening on mine a bit, back by the firewall).  Or it might be that the
outer valve cover gasket (there are two main seperate parts to this gasket
kit, as I think someone already explained) is also shot (the inner one
DEFINITELY is).  If that's true, that would allow all kinds of oil to seep
(or spray?) anywhere around the perimeter of the cylinder head.  Anyway,
seems like those two repairs--valve cover gasket set and TimeSert spark
plug hole repair--are definite needs for you.

Then you need at least the one coil too, right?  I received a lot of advice
about coils which you can find on the list archives under Thanksgiving
Misadventure.  I just switched one in, which was the hardest part of this
whole job, though kind of just a PITA that went fine as long as I took my
time.  Got to do it inside at least!  Not sure what you plan is coil-wise.

The good news in all this is that we are not talking a lot of money.
Gasket kit under $100.  TimeSert is $120-180.  If you find one used known
good coil, I imagine you'd pay less than $50 for it.  Try Force Five Auto
http://www.force5auto.com/specials.htm (email Chris, at the bottom of this
page.  Chris is amazing.  Fast to ship and very reasonable and trust
worthy, as others on the list have also found).  You could see how much for
a full working loom of 5 coils, which would likely be easier to switch in.
Might not be much more.  Again, ask Chris.  So, none of thie chould fun
into very much money.  Let me know if and when you want those valve cover
gasket replacement instructions I have.

Keith

 On Sun, Mar 4, 2012 at 9:23 PM, <b1biker at aol.com> wrote:

> Keith, thanks for the message. It appears that we have exactly the same
> problem; only at opposite ends of the engine. My #1 plug is loose and the
> threads are stripped so I could definetly use the TimeSert tool. What did
> you determine to be the reason for spewing oil in the engine compartment as
> I found my engine compartment coated with oil and no clearly visible source.
> Thanks for your assistance. Gary
>
>
>
>
> -----Original Message-----
> From: Keith Franchetti <skidfranc at gmail.com>
> To: b1biker <b1biker at aol.com>; s-car-list <s-car-list at audifans.com>
> Sent: Sun, Mar 4, 2012 2:15 pm
> Subject: Further Developments -- 94 S4
>
> Hi Gary-
>
> I think I'm the lister who was mentioned as having recently had a similar
> problem.  If you want to look up the story, it's mostly under "Thanksgiving
> Misadventure," I believe.
>
> I had a spark plug loosen up and back out, AND a failure of the valve
> cover gasket, which inundated the plug wells with oil.  I'm pretty sure
> those events were connected, but not sure how.  There was also probably a
> bit of fire in there, which melted and destroyed the boot for that plug (#5
> for me) and that #5 coil.  On top of that, the spark plug hole/threads in
> the head were badly damaged.  Not sure what the situation is with your
> spark plug and the head threads.  The valve cover gasket sure seems to me
> like the culprit on the all that oil.  I also had it spraying onto the
> firewall when I first opened the hood to figure out what was going on (I
> was clearing only hitting on 4 cylinders).
>
> I got the new OEM gasket set (2 main pieces, plus two little half-moon
> pieces that I almost threw away!) from Sunset Audi in Oregon (I'm in VT).
>  Great customer service and competitive price.
> http://www.sunsetimports.com/audi/  I've heard that trying to use other
> than OEM on this, the fit is not quite right and they are harder to
> install.  That job was not too big a deal.  I also got a great set of
> instructions on this valve cover gasket repair (off list) which I could
> forward to you if you'd like.
>
> If your spark plug threads are also damaged, I've got just the tool for
> you.  Not helicoil, as was mentioned, but a much better version of that
> similar idea:  TimeSert.  Let me know if you need it and I can hook you up.
>
>
> As for the coil, that ended up being the biggest PITA, though #5 made it
> as easy as can be.  And I got some great advice for how to change out just
> that one coil.  Fortunately, I had a spare loom/set, and fortunately, the
> one I switched in has worked.  Car is doing fine now.
>
> Good luck.
>
> Keith Franchetti
>
> 96.5 S6 Avant
> 01 A6 2.7T
>