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You can fix the issue by welding a new pin on the flywheel through the opening for the starter, it's happened to a friend of mine too and this is what he did, and it worked fine afterwards...
HTH,
Mihnea
'98 Silver Grey 2.7T S4, dual 2.75" turbo back exhaust with no cats, FMIC, BIG injectors, 10 Bar motorsport fuel pump, modded RS4 turbos, tubular exhaust manifolds, custom intakes, RS4 MAF, Bilstein PSS9, H&R ARBs, 19" BBS CH, custom remap, 511 BHP/505ft-lbs
You can fix the issue by welding a new pin on the flywheel through the opening for the starter, it's happened to a friend of mine too and this is what he did, and it worked fine afterwards...
HTH,
Mihnea
Mik, Yeah, I'm going to try dropping the subframe and drilling, then bonding or welding a pin back in. Easier said than done when you're working on your back on the drive though
Two things.
First the Ecu didn't pick up this failure as a sensor error. It shows the rpm sensor, but not the ign ref sensor.
Secondly, if the failure occurs when the car is running it will shut the engine down. This is contary to what is published elsewhere. The implication was that the car would run until the next restart.
Hope that might help someone one day!
You should be able to hammer it out and insert a new one. It has been done just with the starter out as you seem to have.
Porkkis, Your suggestion was spot on
How can you hammer it out?? The hole is blind, so it can only be removed from the side it went into. Robin (Twoqu) has located the part number so I'll order the part tomorrow. Getting the broken section out will be the difficult task...any suggestions?
Just double checked. It is a blind hole. Even if it wasn't it looks as though the pressure plate would prevent driving it out. Shame, that would have been a relatively easy fix!
As Paul N said, hell of a lot of inconvenience for a small failing, especially as Audi/Bosch made sure the engine could still run with a whole load of sensor faults.
Porkkis, we have had it on good authority that when the pin goes the engine cuts out. This was from someone who had identical fault.
Naah try to unplug the 62 deg sensor with car running and it will not stall.
ECU calculates the position from the starter teeth in this case. Of course if there is something wrong with the starter ring also it can't run... probably checks from hall signal then and if the tooth/rev count varies it stalls. I guess
BTW asked the fellow to tell me again how he did the job. I'll keep you posted.
Thanks, any suggestions would be great
With regard to the failure of the sensor, my car stalled after 100 metres or so, this was when I slowed down due to loss of power. The ECU was most certainly aware that something was wrong. I've also spoken to another member who has experienced the same problem and their car stopped within a few metres of the pin breaking.
I'm almost 100% sure that the feature than Porkkis is referring to is applicable to the hall/CMP sensor (G40) ie No signal on cold crank means no start, but the engine will continue to run if you disconnect it while running.
Thanks Paul.
Initially we didn't suspect the pin as we assumed that the engine would continue running as we checked that out before. We suspected the rpm sensor!
Right according to Audi publication WSP-521-209-00 (covering the 3B engine) it does indeed backup Porkkis claim on this.
G4 & G28 - Substitute function
If either of the sensors fail, the engine cannot be restarted. However, if the reference sensor (G4) fails when the engine is running, the system will use the #1 cylinder signal that was used when the engine was started.
I was also correct about the CMP/G40/Hall sender. According to the same book, in the G40 failure mode the engine will continue to run by using the G4 and G28 signals, but ignition timing is retarded by 6 degrees.
Doesn't quite explain why Steve and another 3B stalled when the G4 pin sheared, except that disconnecting G4 would raise a fault code by nature of the open circuit condition. A sheared pin - resulting in no signal from an otherwise healthy G4 sender would not raise a fault code - hence the engine dies.
Pretty poor bit of fault intolerant programming from Herr Bosch there methinks... Now to try and think of a workaround for this
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