Possible K04 failure after 13,000 Mi and 18 months?

[bennett]

If you have already seen this on audiworld I am sorry for the multi forum post...

About a week ago, after noticing oil on the DS K04, I had a sudden loss of boost. Before this problem I was consistently at 21-22 PSI. Since the day I lost boost I have not been able to build more than 6 PSI.

I am using an Apexi AVC-R, so limp mode will not be a factor.

I have disconnected the boost solenoid and left the wastegate hose loose (therefore leaving the wastegates closed). I still built no more than 5-9 PSI.

I have done a boost leak check and everything is fine.

There has not been any problematic turbo noise.

Other problems that I have been seeing:
1-White / blue smoke (thought it was worn exhaust valve guides)
2-Since replacing O2 sensors recently I have had CEL's for circuit faults
3-Something has been creaking as I steer
4-The exhaust smells more pugnant than before
5-Oil dripping from the drivers side turbo (as mentioned above)
6-Increasing missfires

I am seeking advice on what to do - hoping that it is not really the turbos.

Why would both go at the same time?
Was one already dead and then the second died trying to compensate?
What else could it be if the wastegate are closed and I am still not getting boost?

So many questions. Please tell me that I am missing something!
-----------------------------
01 B5 S4 Chassis 6sp, Black
02 Engine
01 Engine (Spare)
-----------------------------
Stg 3
-----------------------------
TURBOS: RSK04, Coated
MAF: ASP 85mm
CODE: EPL
INJECTORS: Motron 630cc
INTAKE: OE
FILTER: OE Paper
DOWNPIPES: JP Engineering w/ Cats
EXHAUST: Milltek Super Dual
BOOST CONTROLLER: Apexi AVC-R
FLYWHEEL: Resurfaced OE
CLUTCH: VAST Kevlar
PRESSURE PLATE: RS4
INTERCOOLERS: IPP
OTHER: N249 deleted, Innovative Motorsports Wide-band AFR
-----------------------------
COILOVERS: H&R Sport
SWAYS: H-Sport
BRAKES: Brembo GT (Front only, I'm not rich)

------------------------------------ UPDATE ---------------------------------------------


I had the turbos rebuilt by ADP Distributors for $900. One with a new cartridge, one with a new shaft and other bits.

They said that the shaft was scored and the bearings shot.

The rebuilt turbos are in now, still not getting boost! I am maxing out at exactly the same PSI as before the rebuild. WTF!

I am desperate for thoughts on this matter.

[Daft]

It sure sounds like at least the driver's side is done but, let's go over a few items. Is the oil that you saw on the driver's side turbo seeping from between the turbine and the downpipe? If it's simply on the side of the turbo, the installer must not have tightened the oil feed line enough to prevent it from dripping.

Typically limp mode does force you to stay at 5-6psi. Since you arent using an N75, it's not limp mode.

Are you sure that the AVC-R is working properly? I'd get a manual boost controller on there and see if you can make boost with that. If not, you either have a vacuum line issue or two frozen wastegates. (very unlikely)

BTW, leaving the wastegate lines loose will not let them spool up any higher than the spring rate of the actuator. Once you make enough boost to force the actuator open, boost will stop building. This is why you're still only getting 9PSi.

Also, you didn't mention any error codes other than the O2 related ones. Any others you recall seeing?

The creeking as you steer is more than likely a worn tie rod end.

[tumtum411]

i say take it to a local shop that does good work and make them take a quick look at it

[bennett]

DAFT: Thanks. After your post I tried plugging the hose to the wastegates so that they wouldn't move. I built only 9 PSI. It is more than before though!

I will try to test the AVC-R.

[generationjdm]

The theme of the year has been dozens of new k04 failures for no apparent reason, but they are what they are, "ancient old cheap design for top dollar price".. The main excuse has been quality control blahblahblah...

[bennett]

generationjdm, is "failure" your vote on this?

[generationjdm]

It's really hard to say, but from what your saying it sounds like the last few that went that i herd about.. Call some shops and get there read on things.. To me it sounds like you may have a bad seal, if you can get to the turbo wheel try to see if theres any in and out shaft play

[bennett]

Shit. Well I hope not. Do you have any threads on those failures that I can refer to?

[generationjdm]

Just do some searching and you should fine some also you can call Alex at vagmotorsports he's seen tons of them fail recently...

[bennett]

Update:

I had the turbos rebuilt by ADP Distributors for $900. One with a new cartridge, one with a new shaft and other bits.

They said that the shaft was scored and the bearings shot.

The rebuilt turbos are in now, still not getting boost! I am maxing out at exactly the same PSI as before the rebuild. WTF!

I am desperate for thoughts on this matter.

[obijohn22]

sounds like a valvetrain issue or a serious case of blow by on certain cylinders, but that would cause other problems........i don't know. boost leak test is ok but no boost.......have you tried it with just the downpipes on and no cats/exhaust? i have heard of clogged cats and no exhaust flow issues but it's a shot in the dark. I still like the wategates as the problem, but both of them? unlikely.

also, do you have a different ecu you could plug in?

[lrg8683]

Update:

I had the turbos rebuilt by ADP Distributors for $900. One with a new cartridge, one with a new shaft and other bits.

They said that the shaft was scored and the bearings shot.

The rebuilt turbos are in now, still not getting boost! I am maxing out at exactly the same PSI as before the rebuild. WTF!

I am desperate for thoughts on this matter.

i don't know how k04's were fine for so long, now all of a sudden they blow left and right? doesn't make sense.

[bennett]

sounds like a valvetrain issue or a serious case of blow by on certain cylinders, but that would cause other problems........i don't know. boost leak test is ok but no boost.......have you tried it with just the downpipes on and no cats/exhaust? i have heard of clogged cats and no exhaust flow issues but it's a shot in the dark. I still like the wategates as the problem, but both of them? unlikely.

also, do you have a different ecu you could plug in?

I guess I could try another ECU, I have access to an AWE ECU that I used to run with this setup.

What kind oif valvetrain issue do you think this could be?

[saucys4]

i don't know how k04's were fine for so long, now all of a sudden they blow left and right? doesn't make sense.

How many applications are using the RS4 K04's right now? Perhaps the quality control has landed in the pooper as a result of putting more money and emphasis into newer and upcoming systems.

[tike0rz]

i don't know how k04's were fine for so long, now all of a sudden they blow left and right? doesn't make sense.

Global warming?

[Das General]

i don't know how k04's were fine for so long, now all of a sudden they blow left and right? doesn't make sense.

It's called quality control. For large companies like Borg Warner, the ability to overlook all aspects of product can be tough. And all it takes is one bad batch f turbos to come out to create this exact situation at hand.

[Allaidback]

Update:

I had the turbos rebuilt by ADP Distributors for $900. One with a new cartridge, one with a new shaft and other bits.

They said that the shaft was scored and the bearings shot.

The rebuilt turbos are in now, still not getting boost! I am maxing out at exactly the same PSI as before the rebuild. WTF!

I am desperate for thoughts on this matter.

So you can just get K04 turbos rebuilt instead of buying new ones?

[bennett]

So you can just get K04 turbos rebuilt instead of buying new ones?

I wouldn't doubt that the quality control at a large turbo shop is better than that at the factory anyways.