Audi Case Study · 146

Audi A5 oil separator, replaced.

An Audi A5 came in with a check engine light, oil consumption, a rough idle, blue smoke and misfires. The oil separator had failed. Replaced and the PCV system reset.

Job done

Mechanical Repairs Engine Repairs Audi Specialist
Audi A5 parked at the workshop, in for oil separator inspection.

The brief

The A5 had a check engine light on, with increased oil consumption, a rough, unstable idle, poor engine performance, blue smoke from the exhaust, the odd misfire, and a whistling vacuum-leak sound from the bay. He brought it in. That whole list points at the oil separator, the part of the engine's breather system that catches the oil mist the engine breathes out and drains it back to the sump, sending the cleaned vapour back to the intake. A diaphragm inside it regulates the crankcase pressure. When that diaphragm fails and the housing cracks, the pressure isn't regulated, which is the rough idle, the misfires and the whistling, and oil mist gets pulled straight through into the intake instead of being caught, which is the oil consumption and the blue smoke. All of it traces back to that one part, and delaying the fix only adds engine wear and emissions.

Oil and breather residue around the oil separator on the Audi A5.

The diagnosis

On the lift the leak and the breather fault were confirmed at the oil separator, the housing cracked and the diaphragm inside failed, with oil found in the intake side. The codes pointed at the crankcase breather. That's a replacement. The separator is a sealed assembly, you don't patch a cracked housing or a torn diaphragm, so the unit gets changed and the PCV system reset.

The cracked oil separator removed from the engine.

The work

The cracked oil separator came off, and a new genuine Audi-spec unit went in with a fresh diaphragm and seals. The breather hoses were reseated with new clamps so the whole path was sealed again, the oil that had tracked down cleaned off, the stored fault codes cleared, and a short adaptation cycle run on the scanner so the engine relearned its idle with the breather working properly. A road test confirmed the idle had settled, the smoke and the misfires were gone, and there was nothing leaking.

The new Audi-spec oil separator ready to fit.

The outcome

Steady idle, no smoke, no misfires, oil consumption back to normal, no whistling, and the check engine light out after a drive cycle. The A5 went home with the PCV system regulating cleanly. A failed oil separator quietly drinks oil, fouls the intake and roughens the idle the longer it's run, so changing the unit and resetting the system sorted the lot.

Got something similar?

Burning oil or rough idle on your Audi?

If your car is using oil, idling rough, misfiring, or blowing smoke, the team can check the breather system and find the cause. Drop us a message.

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