06 A4 Blown Turbo?

[Endmass]

So I'm driving home. I kick on the defrost and notice a smell.

I get home, park turn the car off. At this point it has no CEL on. Pop the hood and the cat is GLOWING red, and there's oil everywhere on the turbo side of the motor.


Now, I don't beat on this car. My drive from work to home is a massive 1.2 miles. In that time, it was enough to do this (or it was on the brink of failing?) I will note that it's had a whining noise for some time, but I attributed this to a recent change of the serp belt, and timing belt (recent as in last year)


It'd have a missfire code every now and then when cold, I thought it was just from a crusty intake (verified via camera probe, was going to do it this spring)


Link to Gallery:
www.imgur.com/a/jHtfj



Happen to anyone before? Sadly, it's 2 degrees outside so I wont get to tear it apart for a few months.

[crazyquik22023]

If the whine sounds similar to a supercharger whine that is usually the turbine hitting the compressor cover. Sounds like a blown turbo to me. You can remove the intake tube and check for shaft play. If it is as blown as it seems like it is there well be ALOT of shaft play.

[Endmass]

Yup, very supercharger like.

Next question: what cause the failure? Plugged cat from some misfires causing a bit to much back pressure? Plugged cat causing misfires? The PCV system has been giving me problems, I just installed a catch can last month. Oil has a bit of water in it, due to short drives in cold months (I change before 3k miles) Just seems odd.


So at this point I'm looking at getting a turbo rebuilt, and a test pipe (or HFC) Pending a tear-down of coarse. (I might order the test pipe now....)

[crazyquik22023]

Turbo failures are usually from lack of oil. Since you mentioned that your drive home from work is very short that will definitely cause increased carbon build up which could also lead to clogged oil passages/oil pump pickup screen which could lead to turbo damage. Also depending on mileage turbos do just fail overtime.

[Endmass]

It's at 120k.

I do let it warm up a bit before driving, and after.

Now, does it need a k04 or a gt28r.....

[p0isin]

GTX or EFR

[Charles.waite]

Sounds like the oil lin ruptured or a fitting got too loose. I bet the loss of oil pressure from that leak killed the turbo and made that mess everywhere. I would source a used turbo on ebay. You can find them around $3-400 usually.

[audihere06]

I had the same thing happen. I didnt find any oil on the side of the engine but I was sitting at a red light and noticed a smell. 30 seconds later my cel came on for the rear O2 sensor. Ive noticed a whine recently as well. After the cel i cleared it and it didnt come back. A few days later it started consuming oil like crazy and smoking like a chimney from the exhaust. I pulled it off yesterday and it had a shit load of shaft play and a tight spot. Dropped it off at my turbo shop today should hear back tomorrow. My turbo was just rebuilt in june and has about 1500 miles on it.


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[Endmass]

I had the same thing happen. I didnt find any oil on the side of the engine but I was sitting at a red light and noticed a smell. 30 seconds later my cel came on for the rear O2 sensor. Ive noticed a whine recently as well. After the cel i cleared it and it didnt come back. A few days later it started consuming oil like crazy and smoking like a chimney from the exhaust. I pulled it off yesterday and it had a shit load of shaft play and a tight spot. Dropped it off at my turbo shop today should hear back tomorrow. My turbo was just rebuilt in june and has about 1500 miles on it.


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Either they botched the rebuild, or something is causing it to fail.


Do to the sound, I think the oil line ruptured when it seized up. I'll replace the send and return lines as well.


Last turbo I had built was around $400 at my local shop. Think I'll go back to stock unless they have some fun parts laying about.

[audihere06]

Either they botched the rebuild, or something is causing it to fail.


Do to the sound, I think the oil line ruptured when it seized up. I'll replace the send and return lines as well.


Last turbo I had built was around $400 at my local shop. Think I'll go back to stock unless they have some fun parts laying about.

Mine should be under warranty. I havent found any metal shavings or particles in the oil. Hopefully it doesn't happen again. Rebuild was done by Borg Warner.


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[Okedokey]

Blocked CAT?

[Endmass]

It undoubtedly is now.

[Endmass]

Update:

Cat is pulled, looks like a cat. No unusual play in the turbo's shaft and it spins freely. Debating on wither or not to remove, as it seems fine. I do notice a lot of water in the oil (from driving few miles) and an oil leak from somewhere still - since it pissed mostly on the heat shield by the turbo: I assumed it was turbo related. Could just be a pushed out VC gasket? Maybe the funky stuff that build up in the pcv clogged it and it got pushed out?


Also noted the flex section of the downpipe is mostly gone. Best cheap downpipe solution? Already got the JHM test pipe (no emissions test in MI)

[Charles.waite]

Techtonics tuning makes really solid downpipes.

[Endmass]

Slight puddle of oil on the compressor side of the turbo. Normal?

[Charles.waite]

Yea. There's very little you can do about small amounts of oil in the intake piping. It's just a fact of life with turbo cars.

Now if it's like 1/2 a quart then you have some problems. But a few little dribbles is really nothing to concern yourself over and is very normal.

[Endmass]

It was a half quart lasttime I pulled the lower intake plumbing. I was probably the first to do so. Not a lot of oil consumption to raise an issue.

Turbo's out. Lots of buildup on the exhaust vales (carbon) oil on the exhaust manifold gasket. I'm thinking somethings not right with the valve cover. I'll replace it's gasket as well.

The carbon in the exhaust ports, I should be able to clean that with my new fancy soda blaster, eh? I think most of my problem were from a plugged cat, lots of backpressure. It's plugged from misfires at idle, Which after replacing all of the ignition system: I can only attribute to the massive amounts of carbon in the intake.

[vce1232000]

that robbing cat with a test pipe. And dont be afraid to afterwards....lol

[Endmass]

that robbing cat with a test pipe. And dont be afraid to afterwards....lol

The way this thing's been on my wallet, I can't afford to beat on it too much. It's a DD. only did the test pipe due to money constraints, would have loved a HFC instead.

I don't have a carbon footprint, I drive everywhere




I did lowball the PO by $3500, so theirs that.

[Charles.waite]

I think test pipes are bullshit. Spew out noxious fumes all over the place, for no material gain over a good HFC. I really don't see the point.

[Endmass]

I'm not a huge fan of them either. It's $160 cheaper that a hfc that I might still clog up if I don't figure out this issue.

I drive all of two miles a day on average, and if you could see some of the hooptys on the road here, you'd realize that I'm still wayyyy lower emissions than them.

[Charles.waite]

Fwiw clogged cats are not particularly common.

[Endmass]

Fwiw clogged cats are not particularly common.

In cars that rarely get upto temp, it's more likely.

Especially those with misfire issues.

[Charles.waite]

In cars that rarely get upto temp, it's more likely.

Especially those with misfire issues.

Yup. Short trips would be really rough on the cat because it wouldn't ever get to burn off the buildup.

[vce1232000]

I think test pipes are bullshit. Spew out noxious fumes all over the place, for no material gain over a good HFC. I really don't see the point.

Thats your opinion. Sorry you feel that way. the point is more Poooooowa. Unless of course your afraid to ....... Mostly all stage 3 cars utilize a test pipe. Even some KO4 requires them. I think CTS KO4 has the test pipe included in their kits

[Charles.waite]

You can get a HFC with the CTS kit.

Any yea it's only my opinion obviously. Not holding it against anyone, but personally I don't like to harm the environment any more than I have to. Given that the gains from a HFC to a test pipe are pretty minimal, I'll gladly spend more on the HFC and not spew noxious fumes everywhere. Also some HFCs sill pass emissions which is important for me in Seattle.

[vce1232000]

Here's a funny story. I was stuck in traffic with windows down in a breezy day. After some minutes passed I started to get the only . I finally realized I was breathing in my own exhaust fumes getting carbon monoxide poisoning....I was like DAMN wished I had a HFC.......lol

[Endmass]

More findings, now that it's above 50 degrees out:

-Turbo pulled, lots of carbon everywhere. Bought a used core from a member on here, sending that out for a rebuild when it gets here. Between the massive amounts of carbon and heat stress on the turbo's shaft, I don't feel right using it. Not to mention the wastegate flapper is looser than most pornstars.
-Went to plumb the catch can into the turbo drain, so I drained it. No oil in it, just water and gasoline (!!!)
-Pulled coils, number 4 is soaked in oil. Replacing VC gasket


What's odd is the fact I'd only get a misfire CEL every now and then. I think It's a combo of the wrong plugs (bosch sidefire) and the intake being clogged up. I REALLY hope it's not a burned up valve, as I'd HATE to pull the head off the car.

Yes, it's going to get multiple oil flushes after all the new parts go on. Yes, I'll drive it a lot longer distances: My drive to work is all of a mile each way. Right now I'm doing a VCG and then during this week I'll get around to doing a carbon cleaning of the intake. Already bought the soda blaster and everything (including that damn injector tool and seals)


If this damn car didn't drive so nice, I'd burn it to the ground.

[Endmass]

Also,


This explains the poor fuel millage. If I was smarter, I would have checked the a/f via vagcom the first time I got the CEL. I kinda remember why I'm a diesel guy.

[Endmass]

So, Today before work I got the valve cover gasket done, new NGK vpower copper plugs gapped at .030. Lines for the catch can installed, rear o2 removed from old piping. (new o2 going on up front)

Tomorrow:
-New coolant flange and sensor
-New DP and test pipe going in
-Replace fuel filter

Later this week: Carbon cleaning the intake, cleaning injectors of carbon. I swear if this thing doesn't run like new, I'm trading it for a Tesla.

[Trickassfoo]

When you say trading, you mean giving them the car and a bunch of money right?

[Endmass]

When you say trading, you mean giving them the car and a bunch of money right?

Can't even do that. Tesla doesn't have dealers, they're direct.


By "Trade" I mean sell it and put a down payment on a Tesla.

[blackbowtie]

Can't even do that. Tesla doesn't have dealers, they're direct.


By "Trade" I mean sell it and put a down payment on a Tesla.

They will take any car as a down payment towards a new car. I don't think if they would take a Chevy Cobalt, but they'd probably take yours. They just send them to auction. https://www.teslamotors.com/support/trade-ins

[Endmass]

Update:

Rest of the parts are on order (shipped today) from ECS. Bought a better condition used turbo from a member on here, just dropped the turbo off at the rebuilders, that'll take a couple of days.


Need to reinstall the turbo and exhaust bit before pulling the intake to clean. I already have enough pieces laying about.

[audihere06]

Can't even do that. Tesla doesn't have dealers, they're direct.


By "Trade" I mean sell it and put a down payment on a Tesla.

They just built a Tesla dealership here in Charlotte NC.


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[Endmass]

It's like some divine intervention shit going on right now.

Got a call back from the turbo rebuild shop - cracked manifold on that turbo. The one that came off the car has a worn wastegate flapper. Did they not build these to be durable?


It's tempting to go with new oem or a k04. Don't quite have the cash.