The 5 Most Common Audi 4.0T Engine Problems Audi Tuning

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Audi’s 4.0t V8 twin-turbo, commonly referred to as 4.0tt, was first introduced in 2012 in the Audi S6, S7, and S8. It’s a 90-degree V-angle V8 engine that produced 520hp and 479lb-ft torque to the crank. It was not only featured in many Audi vehicles, but was also featured in many Porsche’s, Bentley’s, and Lamborghini’s.

This innovative engine featured an all-new cylinder on demand system that when the engine operates on part load, four of its cylinders are deactivated. This innovation lowered fuel consumption by 5% and also reduced emissions substantially. The 4.0 TFSI v8 was awarded the Digital Trends Engine of the Year.

Audi’s that use the 4.0T

2012-2018 Audi C7 S6
2012-2017 Audi S7
2012-2018 Audi D4 A8
2017-Present Audi D5 A8
2012-2020 Audi D4 S8
2013 – 2019 Audi RS7
2013 – 2018 Audi C7 RS6

Something worth mentioning before getting into the common problems of this engine is, please make sure the replacement parts fit your vehicle before ordering.

Audi 4.0T Engine Problems

Ignition Coil Failure
Turbo Oil Supply Line Filter Clogged
Motor Mounts Failure
PCV Valve/Engine Oil Separator Failure
Thermostat Failure

1. Ignition Coil Pack and Spark Plug Failure

Ignition coils and spark plugs are very common to go out in many Audi’s. The Ignition coils transform the voltage from the battery to a higher voltage for the spark plugs to create a spark and create combustion. The main reason either of these seem to fail is by normal wear and tear or by pushing an engine past its optimal engine conditions.

A good rule of thumb is to change both the spark plugs in the first 35,000 miles, and 40,000 miles thereafter. Whenever an ignition coil goes out, it is best to replace all 8. It may be expensive, but it will be worth it in the end.

Symptoms of Coil Packs/Spark Plugs Failure:

Check Engine Light (CEL) illuminating
Engine misfires
Rough idle
Loss of engine performance
Engine not turning over

Coil Pack/Spark Plug Replacement Options:

When it comes to ignition coils and spark plugs, it is important to replace them all at the same time to give the vehicle a fresh set. If you plan on DIYing this, make sure you have the proper tools and it’ll be a rather easy DIY. If you aren’t looking to DIY and are wanting to take it to a shop, you would be looking at a cost of around ~$1,200 mainly due to the cost of parts.

Buy Here: 4.0T Ignition Coil Pack Replacement
Buy Here: 4.0T Spark Plug Replacement

DIY Difficulty: Intermediate

2. Audi 4.0t Turbo Oil Supply Line Filter Clogged

This is a very common problem when it comes to the Audi 4.0tt and has caused many blown turbochargers. There are many names for this, but pretty much the role of the turbo oil filter is to filter oil before entering the turbocharger to ensure clean oil is going into the turbos. The filters were failing out of the factory because they were getting clogged too quickly and not enough oil was getting to the turbos.

This problem was so common that Audi has addressed the filter with TSB 21 18 30 2044640/5. There have been many updates to the filter by Audi because they realize the issues it was causing. If you have or are looking at an Audi 4.0t engine, make sure this has been replaced or you will be looking at an expensive repair.

Symptoms of Turbo Oil Filter Clogged:

Blown turbochargers
Engine stalls
Engine sputters
Reduced engine performance
Low oil pressure

Turbo Oil Supply Line Filter Replacement Options:

If the turbo oil supply filters haven’t been changed on an Audi 4.0tt you are looking at or currently own, replace them ASAP. This DIY is not the easiest because the filters themselves are not very easy to get to, but if you know your way around the engine, you should be able to get it done. If you are looking to take the vehicle into the shop, you would be looking at a cost of ~$750 mainly due to the cost of labor.

DIY Difficulty: Intermediate

3. Audi 4.0t Active Motor Mounts Failure

Another common 4.0t engine problem was the active motor mounts failing. Active motor mounts were new technology in the Audi 4.0t when they first came out. The purpose of active mounts is to optimally dampen and isolate engine vibrations and noises to ensure a smooth ride.

This problem was also very common that Audi issued another TSB 27 14 22 2036392/2 to address this issue in all 4.0t engines. There are two ways that these can fail: they are either the faulty mounts out of the factory or normal wear and tear have caused them to go bad. Again, if you are looking to own a 4.0t or currently own one, make sure these have been updated to the latest revisions that Audi released.

Symptoms of Active Motor Mount Failure:

Heavy engine vibrations
Impact engine noises – banging, clanking, etc
Engine movement

Active Motor Mount Replacement Options:

There are really two options when it comes to active motor mount failure: replace them with the OEM parts or replace them with the aftermarket part. The aftermarket part is cheaper but has some other improvements over the OEM part. It certainly is not the easiest DIY, but it can be done in a day’s work. This service at a shop can run up a bill of ~$1,000.

Buy Here: 4.0T OEM Active Motor Mount Replacement

DIY Difficulty: Intermediate

4. PCV Valve/Engine Oil Separator Failure

PCV valve or engine oil separators are common to not be very reliable out of the factory from Audi’s or Volkswagen’s. These remove excess gases from the oil before the oil goes into the combustion chamber. If they fail, the engine AFR will be thrown off causing the symptoms listed below.

This part is prone to fail at least once in the vehicle’s lifetime and should be looked at every 60,000 miles. The two main reasons this part fails are: normal wear and tear or by being stuck open or closed.

Symptoms of PCV Valve/Engine Oil Separator Failure:

Rough idle
Engine misfires
Whistling noise coming from the engine
Lean AFR conditions

PCV Valve/Engine Oil Separator Replacement Options:

If an engine oil separator does happen to fail, the best fix is to just replace it with a new one. The replacement part isn’t very expensive and the DIY is pretty straightforward. A shop will charge you about ~$600 split between parts and labor.

Buy Here: 4.0T PCV Valve/Engine Oil Separator Replacement

DIY Difficulty: Easy

5. Thermostat Failure

Thermostat failure is also another common problem seen in many Volkswagen’s and Audi’s engines. A thermostat is crucial in a vehicle’s cooling system. It regulates the amount of coolant that is sent back to the engine and how much is cooled in the radiator before going back to the engine. If a thermostat happens to fail, you will not be able to drive for long because the engine will be prone to overheating.

In 4.0t’s, this was common enough so Audi issued TSB 19J1 to address the problematic thermostat. If the thermostat has not been replaced under the TSB listed above, make sure to get it replaced ASAP. A normal working thermostat should last up to 70,000 miles.

Symptoms of Thermostat Failure:

Engine overheating
Low coolant levels
Engine temperature being sporadic
Whining noise coming from the engine

Thermostat Replacement Options:

When a thermostat goes out on a 4.0tt, the best thing to do is to just replace the entire unit. Again, like the engine oil separator, the parts are relatively cheap and the DIY is straightforward. If you are looking to take it to a shop to replace, you would be looking at a cost of around ~$800.

Buy Here: 4.0T Thermostat Replacement

DIY Difficulty: Easy
Video DIY Guide:

Audi 4.0t Reliability

The Audi 4.0t engine’s reliability gets a bad rep because of the turbo oil supply line filter getting clogged and blowing turbos. Other than the 5% of cases with this issue, if that, the Audi 4.0t engine is pretty bulletproof IF maintenance schedules are followed. Something worth mentioning is that repairs and maintenance on this engine are not cheap, as expected. We wouldn’t expect this engine to last much longer than 120,000 miles without having to pay big bucks for repairs.

Also, if you want to check out more Audi content, here is our write-up on the common problems for a 4.2 V8.

The 5 Most Common Audi 4.0T Engine Problems