ECS KO4 dental drill

[jacobsen]

I've had my KO4 on for about 1 year now, today heading home from the grocery store my turbo suddenly began emitting a loud dental drill sound. Is there anything else that could possibly make that sound? Do I have any kind of warranty from ECS?

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[diagnosticator]

Nothing else I can think of. Inspect the turbo ASAP, check for side play of the compressor impeller and turbine shaft bushings. Make sure the lube oil feed line is clear, not partially plugged with sludge. Replace the lube oil feed line with a new oil feed line to insure the line is not blocked. Check the engine oil pressure at the oil filter base using a pressure gauge connected to the filter base with a 10mm X 1mm thread pitch fitting and a hose to the gauge.

[jacobsen]

Nothing else I can think of. Inspect the turbo ASAP, check for side play of the compressor impeller and turbine shaft bushings. Make sure the lube oil feed line is clear, not partially plugged with sludge. Replace the lube oil feed line with a new oil feed line to insure the line is not blocked. Check the engine oil pressure at the oil filter base using a pressure gauge connected to the filter base with a 10mm X 1mm thread pitch fitting and a hose to the gauge.

okay I should have some time this week...

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[Doug@FrankenTurbo]

Check the fasteners and gasket where the turbo meets the manifold. If you have a leak there, the sound is metallic and drill-like.

[Seerlah]

If it is an RP turbo, they are junk.

[jacobsen]

Check the fasteners and gasket where the turbo meets the manifold. If you have a leak there, the sound is metallic and drill-like.

She's tight on there, I don't think it's loose.

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[jacobsen]

If it is an RP turbo, they are junk.

What's an RP turbo? This is a Borg Warner from ECS.

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[ECS Tuning-Audi]

Seems odd that a Borg Warner turbo would show signs of failure that early. Typically shaft play will accompany the dentist drill sound. Remove your headlight then remove the turbo intake pipe. This will give you access to the compressor wheel. If it has excessive play up and down it would be safe to assume the CHRA is shot.

Jason

[Audi body]

Usually they never fail unless they are starved if oil.

[jacobsen]

is the k04 double channel journal ?

[Doug@FrankenTurbo]

OP -- it's possible you have a premature failure owing to an oil issue. But I'd still recommend you check the gasket at that flange. If it's compromised, you get that sound. If you pull the inlet to feel for shaft play, you are looking for movement fore and aft. Side to side is not important.

[ozMatt]

Hi Doug,

I thought a tiny amount of fore-aft play was normal, and "side-side" play should be zero?
Are you saying if there is fore-aft movement at all the CHRA is on its way out (if not rooted already?)

Cheers, Matt

[jacobsen]

Nothing else I can think of. Inspect the turbo ASAP, check for side play of the compressor impeller and turbine shaft bushings. Make sure the lube oil feed line is clear, not partially plugged with sludge. Replace the lube oil feed line with a new oil feed line to insure the line is not blocked. Check the engine oil pressure at the oil filter base using a pressure gauge connected to the filter base with a 10mm X 1mm thread pitch fitting and a hose to the gauge.

I bought an oil pressure tester with multiple fittings and an excellent easy to read jumbo gauge from harbor freight for 21 bucks on sale, normally 27.
It's a quality tool it comes with a m10 x1 fitting - you will need teflon tape and a bit of a turn to prevent a leak at high rpm the threads seem to bottom out in the hole - http://www.harborfreight.com/engine-...kit-98949.html
I plugged it to the port on the top of the filter housing.
cold start idle 20 degrees - 71
25 minutes at idle 49
40 minutes 37
2k rpm for 5 minutes 64
return to idle 30
idle 10 more minutes 29
2k rpm 62

OP -- it's possible you have a premature failure owing to an oil issue. But I'd still recommend you check the gasket at that flange. If it's compromised, you get that sound. If you pull the inlet to feel for shaft play, you are looking for movement fore and aft. Side to side is not important.

I wiggled the manifold and the turbo and all I could be certain was moving was the whole motor. I will remove the bumper tonight or tomorrow and inspect the turbo. I have to put a new starter in my old spare galant before I can do anything else.

[jayiszraw]

Hi Doug,

I thought a tiny amount of fore-aft play was normal, and "side-side" play should be zero?
Are you saying if there is fore-aft movement at all the CHRA is on its way out (if not rooted already?)

Cheers, Matt

Its actually the opposite. Even a brand new turbo may have some slight side to side especially with no oil. The fore and aft play will tell you if the thrust bearings are shot

[diagnosticator]

Its actually the opposite. Even a brand new turbo may have some slight side to side especially with no oil. The fore and aft play will tell you if the thrust bearings are shot

That is true, however when the turbo makes a dentist drill noise the concern is that the compressor impeller or turbine is touching it's housing wall, that will damage the impeller or turbine.
Sudden excessive bushing radial wear can only be caused by lubrication failure. or severe imbalance from FOD, etc.

[jacobsen]

What do you think about these bearing upgrade kits? I have read the new generation ko3/ko4 are dual channel for better stability? This kit seems to be single channel but more galleries and larger.
http://www.ebay.ca/itm/111685865336?redirect=mobile
And video linked to AZ. https://youtu.be/99yMB5RII1U

[Audi body]

Best bet is to send it back for warranty. At least in my opinion.