Turbo shot or boost leak? (FTG K04 1mo. 2-3k miles)

[B6A4Dave]

Here's a little back story..

My 200k+ mile old K03S shit out on me, so I bought a cheap replacement until I had my other motor together to go to a 30R.

I ended up getting an FTG K04.. needless to say, it made it a month and maybe 2-3k miles before it started screaming. Doesn't sound like the typical dentist drill sound of a failed turbo, sounds like a boost leak.

I pulled my Passenger Lower IC pipe, the one that connectors the compressor housing to the front lower IC pipe off and plugged in the boost leak tester. I learned that my SJP has a SMALL Tiny leak, and my Boost gauge lines need to be redone, but it's not enough of a leak to do what its doing.

I took a couple video's and have just uploaded to YouTube to hopefully get some feedback.

Pre installation I filled the CHRA with Oil and spun the shaft by hand via compressor wheel, when installed I disabled the fuel and ignition and cranked the engine for quite a while in timed bursts as to not damage the starter, but enough to fill the feed lines and CHRA with oil so no malpractice on my behalf on the installation..

Regardless, 0-5 to almost 9-10psi the turbo sounds normally, anything above 10psi it makes the sound seen in the video's.

I dont see where I could have a big enough boost leak to do what its doing.. the first week or so installed, and next 3 or so to follow it ran great and pulled to a steady 23psi. Then one night I drove to work, car ran and sounded great.. next day when I got off I went to drive home and it made this noise..no indication as to why.

With all the bs between Lee (FTG) and XSPower I dont think I have a snowballs chance in hell of getting mine warrantied..all I know is Im out money for a worthless product that needs to be replaced. Any input would be appreciated as to if it is for sure the turbo or a boost leak somewhere I just cant find!

https://www.youtube.com/watch?v=se-GL-Gxwmg
https://www.youtube.com/watch?v=A3V7rExyync
https://www.youtube.com/watch?v=W8aVgq9xTBA

For the record: here is the specific turbo I got from FTG
http://www.ebay.com/itm/301697019303

[diagnosticator]

Sounds like fairly normal high velocity air flow noise to me. My 1+ does the same thing only not as loud. It only occurs at higher boost due to the high mass air flow rate and high velocity air flowing into the air cleaner and in the system piping.

[B6A4Dave]

Sounds like fairly normal high velocity air flow noise to me. My 1+ does the same thing only not as loud. It only occurs at higher boost due to the high mass air flow rate and high velocity air flowing into the air cleaner and in the system piping.

The thing is, it never used to make that sound, and now I have significantly more turbo lag and producing less peak psi.

[Wet0willy01]

Sorry to hear. I was kicking the idea around for one of these on my daily. Now after seeing first hand how xs power can't even built a test pipe or cat back that fits, I would never buy one. Interested to see how you make out. Best of luck.

[Wet0willy01]

And xs powers customer service is a joke. And Lee would never give me a price on the specific turbo I wanted with and inlet pipe. Instead he tried to sell me every other product under the sun.

[B6A4Dave]

Sounds like fairly normal high velocity air flow noise to me. My 1+ does the same thing only not as loud. It only occurs at higher boost due to the high mass air flow rate and high velocity air flowing into the air cleaner and in the system piping.

And xs powers customer service is a joke. And Lee would never give me a price on the specific turbo I wanted with and inlet pipe. Instead he tried to sell me every other product under the sun.

Word has it that Lee has disappeared since XSP and him had a falling out..no warranties on anything, you're just F**ked.. So I get a feeling Ill be going through eBay Claims/Disputes about this. hopefully I can at least get my money back or something.. Im not sure what to do to be honest.

I at least expected 6mo out of it to give me time to get my BT stuff ready.. it wasnt supposed to be a long term solution to my dying K03S but something to hold me over.. not even 2 months and bang

[Wet0willy01]

Contact xs powers customer service. She was a real treat.

[B6A4Dave]

Contact xs powers customer service. She was a real treat.

How does that work when I didnt purchase it directly from them but from FTG?

[Wet0willy01]

Ah true, forgot he had the branded "FTG"

[Steve Bassen]

Wiggle your wastegate arm and see if there's any play in the bushing...

[csosnowski]

I installed one of these FTG K04's in a customer's car to replace a failed K03s. He hasn't had any issues yet, I will keep an eye on it. His car is tip as well so that may be whats saving it.

[diagnosticator]

The thing is, it never used to make that sound, and now I have significantly more turbo lag and producing less peak psi.

More turbo lag and lower peak boost are warning signs for sure. Have you examined the compressor impeller? Maybe the compressor impeller is slipping on the shaft due to a loose impeller nut. A slipping impeller is consistent with all of the symptoms occurring.

[f1torrents]

I have a friend that picked up a brand new set of FTG K04's for a 2.7T

The shaft play on these is immense.
Both in and out, and side to side.

I have seen blown ko3's with over 300,000 Km's with less shaft play.
Not the greatest quality product.

[customa4]

Don't you have to pull the engine to install turbos on the 2.7T? That is one set of turbos I would not cheap out on.

[f1torrents]

Yes you do.
The turbos are not even installed yet, my concerns were enough for him to hold off putting them in until he figures out what his options are.

I'll try to get over and make a video of the shaft play. Mind you. These are brand new.


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[B6A4Dave]

I contacted FTG and due to me not following their ridiculous warranty procedures during installation he's saying I have no warranty..

[f1torrents]

https://www.youtube.com/watch?v=PmZZCjt2ffI

[PreciseD]

https://www.youtube.com/watch?v=PmZZCjt2ffI

Looks like a Frankenturbo lol.....

[B6A4Dave]

Looks like a broken shaft lol.

[f1torrents]

Gonna see how long they hold up under 20+ psi.

I don't have high hopes for them. But oh well.


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[B6A4Dave]

Sounds like fairly normal high velocity air flow noise to me. My 1+ does the same thing only not as loud. It only occurs at higher boost due to the high mass air flow rate and high velocity air flowing into the air cleaner and in the system piping.

Gonna see how long they hold up under 20+ psi.

I don't have high hopes for them. But oh well.


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23psi made it a month...fyi

[diagnosticator]

A slipping impeller is consistent with all of the symptoms occurring.

[f1torrents]

The turbo in my video is brand new, never been installed.
The end nut on the turbine is tight. Just massive shaft play.

It's pretty much a know fact that all these clone ko4's.. Frankenturbo , FTG , CX Racing is all garbage.

Just get original if you want reliability.



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[uzone02]

I got the same noise

https://www.youtube.com/watch?v=A3V7rExyync

Any solution of it ?

running stock k03...

[B6A4Dave]

I got the same noise

https://www.youtube.com/watch?v=A3V7rExyync

Any solution of it ?

running stock k03...

Replace the turbo with non chinese bullshit

[Audi body]

Get a can of seafoam and run it through the intake manifold. You will see if you have exhaust leaks. I had a gasket blow out and it sounded very similar. Worth a shot

[B6A4Dave]

Get a can of seafoam and run it through the intake manifold. You will see if you have exhaust leaks. I had a gasket blow out and it sounded very similar. Worth a shot

That's actually a pretty damn good idea haha!

[uzone02]

That's actually a pretty damn good idea haha!

the seafoam can replace the smoke machine !

[B6A4Dave]

I wont use seafoam unless Im close to an oil change though...not work having that junk in the pan for the next 2k miles. Ill have to wait off a little bit.

[uzone02]

Any easier way to do the smoke test ?

[JQADDINGMACHINE]

Looks like a Frankenturbo lol.....

this was my frankenturbo when i installed it summer of 2014. I emailed doug about it and was told its normal because it's an unprimed journal bearing turbo. is this bad lol? No in an out play though only the side to side in the video.

for the record i've gone 18k miles of abuse at 20psi with no problems

[Denio24]

Unprimed journal bearing? That is one of the most BS things I have ever heard. Tolerances should be VERY tight around .002" inches max radial play for new turbos. I guess Doug thinks that once the "turbo bearing is primed" it magically gains material and clearances tighten lol.

[userbob0001]

I wont use seafoam unless Im close to an oil change though...not work having that junk in the pan for the next 2k miles. Ill have to wait off a little bit.

There are three ways to use it, through the oil, through the fuel, or through the manifold air. You're thinking about the oil method, he's talking about the manifold method.

[Kevin C]

Unprimed journal bearing? That is one of the most BS things I have ever heard. Tolerances should be VERY tight around .002" inches max radial play for new turbos. I guess Doug thinks that once the "turbo bearing is primed" it magically gains material and clearances tighten lol.

Plain bearing turbos run floating bearings. Each floating bearing "set" has two bearing surfaces, each with a running clearance (ID of bushing to shaft, OD of bushing to housing). On the compressor side, that's two surfaces , each with .002" clearance. You have the same thing on hot side, .004" total clearance (using your figure of .002" per journal, from memory, that sound a bit much, probably less).

The end of the shaft has an overhang, its cantilevered off the end of the bearing. Since the bearing to bearing spacing is a large percentage of the overhang, when you wiggle the shaft the apparent clearance seem quite large. When you push the shaft to one side, the front bearing moves back and forth .004" ( total movement), as does the rear bearing. Since the shaft you are pushing on is cantilevered the movement is exaggerated. That's why .002" of clearance results in a fair amount of shaft movement. Take a look at a cross section of a turbo to get a visual understanding of how the compressor wheel is cantilevered on the shaft and how the spacing to the bearing sets exaggerates the bearing clearance.

Add up all the clearances and take into account the bearing spacing and cantilever and .008 to .010" of shaft movement (at compressor nut) is not unreasonable. Some manuals tell you to measure at the center of the shaft, through the oil hole. This of course is turbo dependant, since you need to be able to get to the center of the shaft.

If you put oil in each of these surfaces, its film strength will cushion the allowable movement, it has four surfaces to develop a film on.

I have tested and rebuilt a few turbos and always get a kick out of the no shaft play claim. Of a plain journal bearing turbo (99% of all turbos) if you have no shaft play, you have a seized bearing. End play is a different story and can be held to a much tighter overall tolerance.

Random turbo picture to show the 2 to 1 cantilever of the end of the compressor shaft.

[Denio24]

Ive gotten a little bit of shaft play as well with the k03 i have rebuilt, but it was very minimal, and nothing like what is shown in the video.

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[PSI NRG]

Sorry for the necro bump but did you ever figure out why the turbo was making that noise?

[KHARDa4]

https://www.youtube.com/watch?v=PmZZCjt2ffI

Holy s***!