Here's the rundown. About a 6 weeks ago, I got a CEL, and used my VCDS to pull the code. Secondary Air System fault, recorded 2 times. I cleared it and it didn't come back, so I figured I would keep an eye on it. Soon after, I went in for my 35K service, knowing I would get flagged with TD1 - I didn't really care and was not going to trouble with flashing to stock then back again. Got service and mentioned the CEL, they checked and it was not present since I cleared it - no biggie.
Come last week I got the CEL again, same code. I called the dealership immediately and made an appointment. The got me in last Thurs, and I dropped the car off, but the CEL was gone on it's own - but I didn't clear the code so they could pull it. The SA was going over things and said "looks like you got chipped at Achtuning?" to which I said "Yep." She said "You don't seem that concerned about it," and said "Note really, I have aftermarket intake, exhaust, front brakes, suspension brace, and a very noticeable Podi boost gauge on the steering column. The car is almost out of warranty anyway, and it's been pretty bulletproof." She said she understood that, but wanted me to know Audi has voided my powertrain warranty as a result, and I said I understood that, and have talked to a few people who have had to get things done, and Audi was pretty understanding overall if the problem was obviously NOT related to being chipped/modified.
They ended up having to keep the car overnight due to the length of work (see similar work on BMW M5 here, courtesy of ilspazzaneve - http://www.turnermotorsport.com/t-te...-Build-Up.aspx ). Friday afternoon I got the call to pick it up, and the SA went over things and we talked for a while. First of all, as mentioned in the above link, this can be abated by using Top Tier fuel, due to the better additives, which more completely burn, and the remnants that don't burn are less likely to gunk things up (supposedly). "Drive it like you stole it" was the exact phrase used - do more spirited driving, and ensure the engine is up to temp. Otherwise, there is nothing to actually prevent this from happening on all B8 S4's, it's just a matter of when it will occur.
I'll reiterate: This WILL OCCUR on your car, it might be like me at 36K miles, or it might be at 100K miles. I changed my driving habits substantially a year ago, by taking the vanpool to work 3-4 days a week. This meant that 4 days a week, it drove 5 total miles to drop off my oldest at preschool - and with the area of country I live in, there is no way the engine ever gets up to operating temp during that drive. I apparently need to drive it much harder when I do drive it at operating temps, something I will eagerly work on.
The work was done, and covered by Audi, since it was a known issue (TSB and description of work is in the image), though it was marked as being a "one time only due to being chipped." The cost of the work out of pocket would likely be in the $600-700 range. With the older 3.2's they had to drop the engine, but now they use some sort of new high pressure water jet to clean things out. I'm not certain of the how, the tech was gone already when I was asking, but they must have a way to keep it out of the parts of the engine it shouldn't be in. You can see that the work done involved:
- bumper removal
- coolant drain
- Supercharger removal
- all belts removed
- spark plugs removed
- power steering pump removed
- air filter/tubing removed
- exhaust removed
Looks like the heads were pulled as well, though it was not cited - there was a part use of head gaskets though.

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