Holy #$%& look at my turbo!!

**bagpype** · 12-07-2015 02:22 PM

I knew that my turbo blew. I had just put my newly rebuilt head on, took care of a misfire, took her on a road test. It ran well for about 500 feet then a terrible noise, the worst smoke you've ever seen come out of an exhaust, and no power. Turbo=dead. Pics to follow. Obviously something came off or got in there.
My questions:
This is apparently a K04 and a shite one from ebay I can only assume. How hard is it to downgrade from a K04 to a K03? I do not want to spend $1k on a turbo.
Is there a better source either new or used for an inexpensive K04?
How does something like this happen and where did the metal bits end up?
How do I prevent this from happening again?

**Tanzimur** · 12-07-2015 02:28 PM

Something went south baaad... and get a k04 of this site ive had many buddys even me run theretubos for years now... speedyracer.com

**ECS Tuning-Audi** · 12-07-2015 02:29 PM

We have quality K03 replacements below.

Click HERE to order or for more information

Jason

**bagpype** · 12-07-2015 02:32 PM

Originally Posted by Tanzimur

Something went south baaad...

Well that's for certain. My question is what and why? It seems like a foreign object but what was it? And where did all of the metal bits go??

**MetalMan** · 12-07-2015 02:39 PM

Maybe the hose clamp holding the TIP to turbo inlet was too tight, and caused the turbo inlet to fracture and break off... causing all the damage.

**Tanzimur** · 12-07-2015 02:39 PM

either that or the nut on the end of the turbo turned it self free and so dorth...

**bagpype** · 12-07-2015 02:43 PM

Originally Posted by Tanzimur

either that or the nut on the end of the turbo turned it self free and so dorth...

That is almost what it seems like but where should I check for it now? It had to go somewhere right?

**texasboy21** · 12-07-2015 02:43 PM

A fully supported K04-015 car is only a 15hp upgrade over a fully supported K03 (but the K04 will have slightly more area under the curve).

**SJorge3442** · 12-07-2015 02:44 PM

Originally Posted by bagpype

Well that's for certain. My question is what and why? It seems like a foreign object but what was it? And where did all of the metal bits go??

All those bits are probably in the engine, or atleast traveled through at one point. I'm no turbo expert, but start preparing yourself for a FULL rebuild. That new head, probably garbage. Cylinders, probably toast. Pistons are strong, but depending on the size of those pieces, they too may be trashed. Might be time to source a used working engine.

**USAF Long** · 12-07-2015 02:50 PM

I'm not so sure that it's only a 15 hp gain over a maxed K03. I've yet to see a K03 put down over 250 whp.

**walky_talky20** · 12-07-2015 02:59 PM

I generally loathe the term "blown" for car parts. "My coil packs are BLOWN", "I BLEW my ECU", etc. Nothing exploded so the term makes no sense.

You totally blew that turbo. Completely blown.

**DansB6** · 12-07-2015 03:00 PM

Been there, not as bad though lol.

**bagpype** · 12-07-2015 03:02 PM

[QUOTE=DansB6;11239219]Been there, not as bad though lol.
And was your engine in need of a rebuild? Where did you find the debris went?

**bagpype** · 12-07-2015 03:03 PM

Originally Posted by walky_talky20

I generally loathe the term "blown" for car parts. "My coil packs are BLOWN", "I BLEW my ECU", etc. Nothing exploded so the term makes no sense.

You totally blew that turbo. Completely blown.

Why don't you try and be more constructive? No offense but your opinion of the verbiage I chose to use adds absolutely nothing to this conversation. Thanks for being rude though.

**texasboy21** · 12-07-2015 03:17 PM

Originally Posted by USAF Long

I'm not so sure that it's only a 15 hp gain over a maxed K03. I've yet to see a K03 put down over 250 whp.

K04-015 dosnt make 250whp (cannot flow enough air. 250+ WHP is GTRS, FT, etc. territory.

http://www.audizine.com/forum/showth...other-K04-dyno

http://www.audizine.com/forum/showth...=1#post4357406

http://www.audizine.com/forum/showth...=1#post5144823

**AudiTechS4** · 12-07-2015 03:17 PM

pretty sure your reading his comment wrong . hes saying you can use the word blown because you blew a part of the inlet off lol.

**DansB6** · 12-07-2015 03:25 PM

Originally Posted by bagpype

Been there, not as bad though lol.
And was your engine in need of a rebuild? Where did you find the debris went?

No the engine was fine, i removed my turbo inlet hose and all the hoses that connect to it and from one of the hoses i had a nut that fell out.

**Seerlah** · 12-07-2015 03:32 PM

Originally Posted by AudiTechS4

pretty sure your reading his comment wrong . hes saying you can use the word blown because you blew a part of the inlet off lol.

Not to mention Keith is one of the most knoelwedable on his site when it comes to technical issues for this particular engine. But yea OP, he was on your side as far as terminology goes.

Very much looks like self destruction. Nut backed off wheel and shredded your wheel, with the assistance of the comp housing as the wheel moved down the shaft. Metal bits will be inside your charge piping. I would suggest you reverse blow out each section with an air compressor.

**bagpype** · 12-07-2015 03:35 PM

Originally Posted by SJorge3442

All those bits are probably in the engine, or atleast traveled through at one point. I'm no turbo expert, but start preparing yourself for a FULL rebuild. That new head, probably garbage. Cylinders, probably toast. Pistons are strong, but depending on the size of those pieces, they too may be trashed. Might be time to source a used working engine.

There is an aftermarket front mount intercooler. They would have had to travel past that no?

**Seerlah** · 12-07-2015 03:38 PM

Yes. But it doesn't take much to move small aluminum peices with an engine that works like a big vacuum pump and velocity in your charge pipe meant to feed the engine with air.

The rebuild part is extreme. Just reverse blow out the charge piping, replace turbo and go from there. I would be more concerned of getting that nut out, along with other chunks of larger mass.

**Let it snow** · 12-07-2015 03:44 PM

The lower air plumbing likes to accumulate oil. So hopefully that is where the metal particles have landed and not in your engine. Good luck OP.

**SJorge3442** · 12-07-2015 03:45 PM

Originally Posted by Seerlah

Yes. But it doesn't take much to move small aluminum peices with an engine that works like a big vacuum pump and velocity in your charge pipe meant to feed the engine with air.

The rebuild part is extreme. Just reverse blow out the charge piping, replace turbo and go from there. I would be more concerned of getting that nut out, along with other chunks of larger mass.

Yeah I came off a little strong. Little pieces can totally make way through the intercooler, but larger pieces wont. Like Seerlah said, reverse blow the piping and see what comes out.

**Seerlah** · 12-07-2015 03:52 PM

Just looked at the pic again. I would not be surpirised if the nut already found it's way out. Or to better put it, made it's own way out.

**bagpype** · 12-07-2015 04:06 PM

Originally Posted by AudiTechS4

pretty sure your reading his comment wrong . hes saying you can use the word blown because you blew a part of the inlet off lol.

If that's the case then I apologize for firing back. His meaning was lost in text translation I guess.

**walky_talky20** · 12-07-2015 04:43 PM

^Indeed. Sorry about that. What I meant was that this is one of those times where "blown" totally applies.

Definitely chase down as much of the shrapnel as you can.

**Seerlah** · 12-07-2015 09:38 PM

Reverse blow out with an air compressor with the charge pipe pieces separately. No sense in blowing metal peices into other sections of your charge pipe in case you were going to go this route (yes, many would).

**KHARDa4** · 12-07-2015 09:49 PM

Originally Posted by texasboy21

A fully supported K04-015 car is only a 15hp upgrade over a fully supported K03 (but the K04 will have slightly more area under the curve).

I'm interested to see a k03 making 256/298 where is this?

**Charles.waite** · 12-07-2015 11:31 PM

Originally Posted by bagpype

Why don't you try and be more constructive? No offense but your opinion of the verbiage I chose to use adds absolutely nothing to this conversation. Thanks for being rude though.

He was being serious. As in "usually people throw that term around without having actually blown something. but in your case it was DEFINITELY a proper use of the word blown."

At least thats how i read it.

**walky_talky20** · 12-07-2015 11:34 PM

Thanks, Charles.

**G-Ride** · 12-08-2015 01:28 AM

Originally Posted by bagpype

I knew that my turbo blew. I had just put my newly rebuilt head on, took care of a misfire, took her on a road test. It ran well for about 500 feet then a terrible noise, the worst smoke you've ever seen come out of an exhaust, and no power. Turbo=dead. Pics to follow. Obviously something came off or got in there.
My questions:
How does something like this happen and where did the metal bits end up?

I reckon the compressor nut at the end of the shaft came loose and bounced around the inlet. That break on the inlet housing looks like outward force.

**texasboy21** · 12-08-2015 07:24 AM

Originally Posted by KHARDa4

I'm interested to see a k03 making 256/298 where is this?

Doesnt exist. K04-015 wont be making this power either. Did you see the dyno links I posted?

**bagpype** · 12-08-2015 08:17 AM

Originally Posted by walky_talky20

^Indeed. Sorry about that. What I meant was that this is one of those times where "blown" totally applies

Lol, now I see what you meant! I too am sorry for firing back because I misconstrued your meaning.

**walky_talky20** · 12-08-2015 10:52 AM

You're forgiven...this time. ;)

On the other hand, you are completely right about the post not contributing anything useful to the discussion. That's fair and I will work on that.

**bagpype** · 12-08-2015 12:23 PM

This deceased turbo was a knockoff K04. What do you all suggest I replace it with? Will a K03 bolt up? If so, what should I look for in a used one? Which cars came with the turbo I may need?

**Charles.waite** · 12-08-2015 12:59 PM

Depends on if your car was tuned for that k04. If it was/is, a k03 might present some problems.

Personally I would find a good condition used OEM k03, have it rebuilt, pop it in and get reflashed to a good k03 big injector tune (obviously buying the requisite injectors that the tune calls for). Bumping up to a k04 doesn't really give you much more than a big injector k03 will give you and to me it's not really worth the expense.

This all depends on if you're running a proper k04 tune though.

**PreciseD** · 12-08-2015 01:02 PM

Damn is that an FT lol

**bagpype** · 12-08-2015 01:17 PM

Originally Posted by Charles.waite

Depends on if your car was tuned for that k04. If it was/is, a k03 might present some problems.

Personally I would find a good condition used OEM k03, have it rebuilt, pop it in and get reflashed to a good k03 big injector tune (obviously buying the requisite injectors that the tune calls for). Bumping up to a k04 doesn't really give you much more than a big injector k03 will give you and to me it's not really worth the expense.

This all depends on if you're running a proper k04 tune though.

This is great info. How do I know if it was tuned for the k04?

**Charles.waite** · 12-08-2015 01:31 PM

Thats an excellent question and one I don't know how to answer.

You might be able to send your ECU to someone (ddillenger, or a few other guys) and they could pull the bin file and see if its stock maps or altered in any way. My guess, given the apparent quality of the ebay k04, that its not actually tuned for it, but I could be wrong.

FWIW, everyone seems to love Motoza and he sells a VERY affordable big injector file for the stock k03. Not sure if he has anything for the k04-15 since its not proven a very popular upgrade given its decidedly "meh" performance over a stock k03.

**bagpype** · 12-08-2015 02:18 PM

I wonder if someone with a vag com can take a peek and see if anything has been modified in the ECU? The guy has a full 3 inch stainless exhaust and a ginormous front mount intercooler on it. The exhaust and intake manifolds look stock but whatever it is I'm going to go back with a k03 if the k04 is not a worthy replacement.

**Charles.waite** · 12-08-2015 02:23 PM

Originally Posted by bagpype

I wonder if someone with a vag com can take a peek and see if anything has been modified in the ECU? The guy has a full 3 inch stainless exhaust and a ginormous front mount intercooler on it. The exhaust and intake manifolds look stock but whatever it is I'm going to go back with a k03 if the k04 is not a worthy replacement.

IF its got a legitimate k04 tune and it has the proper supporting mods (sounds like it probably does, and given that, its possible its got a legit k04 tune) then I would just buy an OEM BorgWarner K04-15. Since its already setup for that you might as well keep it. The K04 is a bolt on turbo so the manifolds don't need to be changed for it.

Not sure if you can peek into the ECU enough from within VCDS to tell if its tuned or not though.