1993 AUDI S4 Fuel System, Gasoline Problems

I OWN TWO OF THE ORIGINAL AUDI S4'S, BOTH 1993 MODELS. MY DAUGHTER WAS DRIVING ONE OF THESE CARS IN 2007 AND THE THROTTLE STUCK OPEN SO THAT THE ENGINE RACED UNCONTROLLABLY. SHE WAS ABLE TO PUT THE CLUTCH IN AND STOP THE CAR AND TURN THE ENGINE OFF. THEN SHE HAD THE CAR TOWED TO THE NEAREST REPAIR SHOP. IT WAS DISCOVERED THAT A PLASTIC PART ON THE TIP OF THE THROTTLE CAM HAD BROKEN OFF AND AS A RESULT THE THROTTLE CABLING MECHANISM STUCK IN THE PARTIALLY "OPEN" POSITION. I HAD THE THROTTLE CAM REPLACED WITH AN ALL STAINLESS STEEL CAM WHICH CANNOT BREAK DOWN AS A RESULT OF HEAT, AS PLASTIC OR A SIMILAR PRODUCT CAN DO. I HAD OEM CAMS REPLACED IN BOTH S4'S. AUDI DEALER WAS NOTIFIED OF THE PROBLEM IN OCTOBER 2007. I HAVE RECOMMENDED TO AUDI THAT ALL 1992-1997 S4 AND S6 MODELS BE RECALLED AND THAT ALL THROTTLE CAMS BE REPLACED WITH AN ALL STAINLESS STEEL CAM (FOR EXAMPLE, ONE FABRICATED BY 034 MOTORSPORT IN FREMONT, CA.) AT LEAST ONE OTHER INSTANCE OF UNINTENDED ACCELERATION, DUE TO FAILURE OF THE OEM THROTTLE CAM, HAS BEEN REPORTED ON THE "WEB" -- IN FACT THAT REPORT LED ME TO 034 MOTORSPORT'S SOLUTION. I KNOW I NEVER RECEIVED, FROM AUDI, A NOTICE OF THIS POTENTIAL PROBLEM. DATE SHOWN BELOW IS APPROXIMATE. I WOULD HAVE TO FIND THE TOWING BILL TO BE PRECISE. *TR

Mileage: 118,000

I RUN A SMALL REPAIR SHOP AND HAVE SEEN A NUMBER OF AUDI VEHICLES FROM 1986 TO 1998 WHICH HAVE STEEL GASOLINE LINES THAT COLLECT ROAD SALT AND RUST IN THE RUBBER SUPPORT GROMMETS ATTACHED TO THE CHASSIS. THE RUST CAUSES A PINHOLE LEAK WHICH THEN BEGINS TO SPRAY GASOLINE ON THE EXHAUST SYSTEM. I HAVE SEEN 5 OR 6 VEHICLES LIKE THIS IN THE PAST 5 YEARS AND SAW ANOTHER ONE LAST WEEK. *TR

I HAD PREVIOUSLY CONTACTED NHSTA REGARDING FUEL LINE LEAKS IN THE ENGINE COMPARTMENT OF THE EALRY S4 AND S6 MODELS. THIS RESULTED IN THE "KY" RECALL CAMPAIGN. MORE RECENTLY, SOME OWNERS HAVE BEEN DISCOVERING LEAKS IN THE FUEL LINES GOING FROM THE REAR OF THE CAR TO THE FRONT. THESE LEAKS OCCUR AT THE POINT WHERE THE FUEL LINE GOES THROUGH RUBBER ISOLATION/MOUNTING BLOCKS. MOISTURE ACCUMULATES AT THESE POINTS AND CORRODES THE FUEL LINE RESULTING IN LEAKS. I DISCOVERED THIS ON MY OWN CAR IN EARLY 2002 AND I KEEP HEARING FROM MORE AND MORE PEOPLE FINDING THE SAME THING. THESE CARS HAVE BEEN EXTREMELY GOOD IN OTHER AREAS BUT THE FUEL SYSTEM PLUMING LEAVES MUCH TO BE DESIRED. DT

FUEL LINE FAILED WHERE BRAIDED LINE MEETS SOLID BRASS LINE. HAS HAPPENED IN MANY OTHER CARS OF THIS MODEL RELATIVE TO THE TOTAL NUMBER SOLD.

FAILURE IS WHERE HOSE FROM FILTER IS PRESS FIT TO METAL FUEL LINE

THE FAILED FUEL LINE WAS CUT OFF AND REPLACED WITH FUEL INJECTION HOSE AND CLAMPS.BY MY AUDI TRAINED MECHANIC. THIS REPAIR WAS NOT SUCCESSFUL AND THE FUEL BEGAN LEAKING AGAIN ON APRIL 1, 1999. I CONTACTED AUDI OF AMERICAN AT THE ADVISE OF THE AUDI S CAR INTERNET WEBSITE. MANY OTHER OWNERS HAD POSTED THE SAME PROBLEM. AOA INTERVENED AND THE REPAIR WAS MADE AT NO COST BY SCHAUMBURG AUDI IN ILLINOIS.

THE FUEL LINE FAILURE OCCURS INCHES FROM THE TURBO, CREATING A DANGEROUS FIRE HAZARD!

FUEL LINE LEAK...NOTICED FAINT FUEL SMELL ON MORNING OF 6/5/99 (COLD WEATHER THAT MORNING).. THIS PROBLEM HAS BEEN FOUND BY SEVERAL OTHER OWNERS. I HAVE NOT BEEN TO A DEALER ABOUT IT, BUT I KNOW THAT IT IS A PROBLEM WITH MY CAR.

PLEASE SEE WEB SITE S-CARS.ORG F.A.Q RE LEAKING FUEL LINES.

METAL FUEL LINE LEAKING ONTO ENGINE COMPARTMENT CAUSING FUMES TO ENTER PASSENGER COMPARTMENT OF VEHICLE. NLM