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AWE Suggesting CAT Blown on 2011 S4

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Old 07-16-2014, 05:16 PM   #1
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Default AWE Suggesting CAT Blown on 2011 S4

Hello All,

It's been awhile since I've had the pleasure of being on these forums. Sadly life got in the way.

I've been working with AWE to address two issues with my exhaust. The first issue was corrosion on the Quad Black Diamond tips. After sending them photos they are willing to replace them.

Second, but most important issue happened while driving on the highway. Between shifts (the burp sound you normally hear) the car shot out a dirty white looking cloud out of the tailpipe (seen in my rear view mirror). Since then the sound from the exhaust hasn't been the same.

Once I got home I saw grey residue on the right tips of the exhaust. After a couple of days the residue lessened and no more debris (powder) is coming out of the exhaust.

What's been checked (Car is out of warranty 98,000km):
  • Scanned the codes, and found a fault with the coolant sensor
  • Brought into the dealership to check the engine and coolant levels
  • Coolant sensor was found faulty and replaced
  • Check Engine light came on and found that the regulating flap for the intake was malfunctioning
  • Adaptation was performed on the regulating flap and corrected
  • Dealership found no other issues with the car
  • Double checked the codes myself when I got home and the system is clear
  • No faults for O2, CATs, or emissions

Questions:
  • If this was a CAT issue why hasn't the car lit up like a Christmas tree with errors? (There are sensors right on the CATs. I've monitored them in real time)
  • The sound appears to be coming from a resonator. Can't the baffling have caused this issue?
  • The dealership thought its an exhaust related issue... and AWE thinks it's the CATs. Have their been any CAT failures with these cars? I haven't seen any.

Image below of what I saw...
Thanks in advance everyone. Btw this car has never seen a track... but I do enjoy driving it

Click the image to open in full size.
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Old 07-16-2014, 07:20 PM   #2
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Chatting with a few friends... its starting to sound like part of the CAT is gone. Are there any bolt on high flow cats? I don't want OEM anymore... and not paying to have them installed...
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2011 S4 Meteor Grey Pearl/S-Tronic/Premium(Canada)/Black&Black Silk Nappa/19" alloy wheels/Nav/Bang&Olufson/Audi Drive Select/3M/25% Tint all around/PPS Paint sealant/Hoen H11 Endurance/APR Carbonio Stage I & II/STaSIS Tune/AWE Resonated Exhaust
--
VAG Mods:
Disabled:
Wink, Nav & Phone message while driving
Enabled: Ambient Interior Lighting, Automatic Gear Selection in DIS, Batt Meter, DRL via MMI, Hidden Menu, Lap Timer, Remote Windows and Sunroof, ADS set to Individual, Adaptive brake lights, VIM, TPMS
Have a VAG cable as well
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Old 07-17-2014, 06:05 AM   #3
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If it's truly the CATs does the engine have to be dropped to access them?
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--
VAG Mods:
Disabled:
Wink, Nav & Phone message while driving
Enabled: Ambient Interior Lighting, Automatic Gear Selection in DIS, Batt Meter, DRL via MMI, Hidden Menu, Lap Timer, Remote Windows and Sunroof, ADS set to Individual, Adaptive brake lights, VIM, TPMS
Have a VAG cable as well
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Old 07-17-2014, 09:54 AM   #4
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Well checked the codes and it appears that I have carbon buildup. I've been asking the dealership all along if I could have tossed out ash from carbon buildup and they said if I had carbon buildup I'd know about it. Explained about hesitation and they shrugged it off. They did however provide me with the codes to look for that is covered by the extended warranty for carbon buildup on our cars. Today I got BOTH codes...

Any thoughts guys?!? Wow this forum is silent now... not how I remembered it lol

If it was the CATs I found two ways of doing it. Lowering the engine or removing... sigh.. Hope this isn't an issue to.

Codes
8931 - Secondary Air Injection System: Bank 1
P0491 00 [237] - Insufficient Flow
MIL ON - Confirmed - Tested Since Memory Clear
Freeze Frame:
Fault Status: 00000001
Fault Priority: 2
Fault Frequency: 1
Mileage: 98327 km
Date: 2014.07.16
Time: 08:02:31

8932 - Secondary Air Injection System: Bank 2
P0492 00 [237] - Insufficient Flow
MIL ON - Confirmed - Tested Since Memory Clear
Freeze Frame:
Fault Status: 00000001
Fault Priority: 2
Fault Frequency: 1
Mileage: 98327 km
Date: 2014.07.16
Time: 08:02:31
__________________
2011 S4 Meteor Grey Pearl/S-Tronic/Premium(Canada)/Black&Black Silk Nappa/19" alloy wheels/Nav/Bang&Olufson/Audi Drive Select/3M/25% Tint all around/PPS Paint sealant/Hoen H11 Endurance/APR Carbonio Stage I & II/STaSIS Tune/AWE Resonated Exhaust
--
VAG Mods:
Disabled:
Wink, Nav & Phone message while driving
Enabled: Ambient Interior Lighting, Automatic Gear Selection in DIS, Batt Meter, DRL via MMI, Hidden Menu, Lap Timer, Remote Windows and Sunroof, ADS set to Individual, Adaptive brake lights, VIM, TPMS
Have a VAG cable as well
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Old 07-17-2014, 10:08 AM   #5
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I would hope the Cats are covered there in Canada. In States the Cats are supposed to be warranted for 100k miles or more. 61k miles (98k Kms) seems a bit soon for carbon build-up problems (at least I hope so!). Quality gasoline and occassional bottle of Techron should help extend...

Any other hi-mileage S4 owners have this issue? I hear Direct Port Injection cars are more susceptible to carbon build-up problems (especially v8-RS4's).
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Old 07-17-2014, 10:13 AM   #6
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Quote:
Originally Posted by SpeedTriplemark View Post
I would hope the Cats are covered there in Canada. In States the Cats are supposed to be warranted for 100k miles or more. 61k miles (98k Kms) seems a bit soon for carbon build-up problems (at least I hope so!). Quality gasoline and occassional bottle of Techron should help extend...

Any other hi-mileage S4 owners have this issue? I hear Direct Port Injection cars are more susceptible to carbon build-up problems (especially v8-RS4's).
Well hopefully with a TD1 that CATs would be covered...didn't think it was covered outside of 80,000km I've read on here before that people have had carbon build-up issues with these cars. Actually with less mileage than my car. Just pondering if it would have tossed out ash.

Car only sees Ultra 94. On a side note I was told even with a TD1 the cleaning of the carbon build-up would be covered. (As per the note sent out by Audi Canada)

Audi Canada Warranty -- From their website
New Vehicle Limited Warranty

The philosophy behind our Audi protection program is quite simple. You drive the car, we back it for 4 years or 80,000 km. Only those who build cars this well would dare to protect them this comprehensively, and offer such extensive service packages.

As an owner of a new vehicle, you will receive:

The first scheduled maintenance service at 8,000 km or 12 months, whichever comes first, free of charge.
4 years or 80,000 km, which ever comes first, new vehicle limited warranty.
12-year limited warranty against corrosion perforation.
Audi 24-hour Roadside Assistance for 4 years.
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2011 S4 Meteor Grey Pearl/S-Tronic/Premium(Canada)/Black&Black Silk Nappa/19" alloy wheels/Nav/Bang&Olufson/Audi Drive Select/3M/25% Tint all around/PPS Paint sealant/Hoen H11 Endurance/APR Carbonio Stage I & II/STaSIS Tune/AWE Resonated Exhaust
--
VAG Mods:
Disabled:
Wink, Nav & Phone message while driving
Enabled: Ambient Interior Lighting, Automatic Gear Selection in DIS, Batt Meter, DRL via MMI, Hidden Menu, Lap Timer, Remote Windows and Sunroof, ADS set to Individual, Adaptive brake lights, VIM, TPMS
Have a VAG cable as well
--
www.smileto.ca

Last edited by TO407S4; 07-17-2014 at 10:17 AM.
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Old 07-17-2014, 02:09 PM   #7
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Had a chat with the dealership. Car goes in tomorrow for a scan and sent to Audi Canada for approval. They said it'll be approved due to the nature of the fault. (engine design)

The CATs they believe are fine and are covered for 7yrs. He said to wait for codes...
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Old 07-19-2014, 05:14 AM   #8
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Picked up the car. Exhaust note is still the same. They cleaned the carbon build up, and the cars hesitation appears to be gone. They are emailing me the statement of work. I'll post details on what was done if anyone is interested.

I have to say after complaining at the dealership and explaining that I received the extended warranty for carbon build up, they just did the work without the TD1 run around
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Old 07-21-2014, 02:01 PM   #9
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Quick update:

The car is still shooting out grey debris and I contacted the dealership letting them know that I still think there is an issue with the CAT. They assured me it wasn't.
Today my check engine light came on and when I scan the logs, it clearly points to the CATs.

This dealership "was" mod friendly and pushed mods back when I went to buy the car. This is because they have their own tuning division. Since the CATs are covered for 7yrs I really hope I don't get the run around.

Well I'm two for two... carbon buildup and CAT..
1 Fault Found:
6093 - Catalyst System; Bank 1
P0420 00 [237] - Efficiency Below Threshold
MIL ON - Confirmed - Tested Since Memory Clear
Freeze Frame:
Fault Status: 00000001
Fault Priority: 2
Fault Frequency: 1
Mileage: 98542 km
Date: 2014.07.20
Time: 11:22:27
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2011 S4 Meteor Grey Pearl/S-Tronic/Premium(Canada)/Black&Black Silk Nappa/19" alloy wheels/Nav/Bang&Olufson/Audi Drive Select/3M/25% Tint all around/PPS Paint sealant/Hoen H11 Endurance/APR Carbonio Stage I & II/STaSIS Tune/AWE Resonated Exhaust
--
VAG Mods:
Disabled:
Wink, Nav & Phone message while driving
Enabled: Ambient Interior Lighting, Automatic Gear Selection in DIS, Batt Meter, DRL via MMI, Hidden Menu, Lap Timer, Remote Windows and Sunroof, ADS set to Individual, Adaptive brake lights, VIM, TPMS
Have a VAG cable as well
--
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Old 07-21-2014, 05:16 PM   #10
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Any suggestions...please let me know
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2011 S4 Meteor Grey Pearl/S-Tronic/Premium(Canada)/Black&Black Silk Nappa/19" alloy wheels/Nav/Bang&Olufson/Audi Drive Select/3M/25% Tint all around/PPS Paint sealant/Hoen H11 Endurance/APR Carbonio Stage I & II/STaSIS Tune/AWE Resonated Exhaust
--
VAG Mods:
Disabled:
Wink, Nav & Phone message while driving
Enabled: Ambient Interior Lighting, Automatic Gear Selection in DIS, Batt Meter, DRL via MMI, Hidden Menu, Lap Timer, Remote Windows and Sunroof, ADS set to Individual, Adaptive brake lights, VIM, TPMS
Have a VAG cable as well
--
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Old 07-22-2014, 05:02 AM   #11
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Quote:
Originally Posted by TO407S4 View Post
Any suggestions...please let me know
I'm being told they won't cover it. Sad when both the dealership and their tuning shop was pushing the mods. I was assured if be supported. I'm beside myself to say the least
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Old 07-22-2014, 06:25 AM   #12
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Spoke to the GM and they have assured me that they stand behind their word and product. I'll provide an update once I know more or the work is done
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Old 07-28-2014, 06:32 PM   #13
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Hello all,

The dealership was great and in the end the carbon buildup and bank 1 CAT were replaced under warranty. The Bank 1 CAT doesn't require the engine to be dropped. They do however have to remove the subframe to get at it.

I'm waiting on my bill from them. If anyone is interested in the services performed let me know and I'll update the thread.
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2011 S4 Meteor Grey Pearl/S-Tronic/Premium(Canada)/Black&Black Silk Nappa/19" alloy wheels/Nav/Bang&Olufson/Audi Drive Select/3M/25% Tint all around/PPS Paint sealant/Hoen H11 Endurance/APR Carbonio Stage I & II/STaSIS Tune/AWE Resonated Exhaust
--
VAG Mods:
Disabled:
Wink, Nav & Phone message while driving
Enabled: Ambient Interior Lighting, Automatic Gear Selection in DIS, Batt Meter, DRL via MMI, Hidden Menu, Lap Timer, Remote Windows and Sunroof, ADS set to Individual, Adaptive brake lights, VIM, TPMS
Have a VAG cable as well
--
www.smileto.ca
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Old 09-18-2014, 08:49 AM   #14
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Quote:
Originally Posted by TO407S4 View Post
Hello all,

The dealership was great and in the end the carbon buildup and bank 1 CAT were replaced under warranty. The Bank 1 CAT doesn't require the engine to be dropped. They do however have to remove the subframe to get at it.

I'm waiting on my bill from them. If anyone is interested in the services performed let me know and I'll update the thread.


I'm having the same exact issue! I have the AWE track edition for my 2012 B8 S4. I thought the exhaust was blown because I was blowing out white chunks of fiberglass material and lots of dust! I took it into my local Audi dealer and they could not find anything wrong. So, I contacted AWE again and they pointed their fingers at the CAT. So I took it into AUDI again and they gave me a loaner and told me they were going to order the CAT for me.

Then, 2 days later they call me and tell me that they cannot order the CAT because my car has been modified. They didn't scan it or flag it into their system, but told me that because of the exhaust and having the ECu flashed, they have to void the warranty. This is a bunch of BULL**** as they promote modifying cars and supposed to be MOD friendly.

Was your car's ECU flashed? They are telling me that it will cost $2,700 just for the CAT. I refuse to pay this price for the CAT. What steps can I take to get this taken care of?

Any advice would help! I paid this dealer to examine the CAT ($100) and they told me everything is fine with the car and deems the care safe to drive. Now that the CAT is blown (AutoZone read the engine light code) and tehy deemed it safe to drive two times, would they be liable for any damages done to the car based on a blown CAT???
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Old 09-26-2014, 05:39 AM   #15
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The CAT is covered under another warranty entirely. Your exhaust and your ECU change shouldn't have anything to do with it. My situation was a little bit different because the dealership and tuning shop were owned by the same company. They stated they stood behind their work and when it counted they did.

I'd suggest getting a highflow CAT if your going to replace it. A lot less money as well...
My engine didn't have to be dropped to put in the CAT like the dealership originally thought. They just had to drop the subframe.

Keep us posted on what happens. What side blew? I'm just curious if it was the same side as me.
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--
VAG Mods:
Disabled:
Wink, Nav & Phone message while driving
Enabled: Ambient Interior Lighting, Automatic Gear Selection in DIS, Batt Meter, DRL via MMI, Hidden Menu, Lap Timer, Remote Windows and Sunroof, ADS set to Individual, Adaptive brake lights, VIM, TPMS
Have a VAG cable as well
--
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Old 09-30-2014, 09:20 AM   #16
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Just my .02 cents if considering a "high-flow" "lower cost" cat. The weld joints on many of these are inferior to the original and from experience on another car, they have cracked and leaked after a short time.
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Old 09-30-2014, 09:20 AM
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