new turbos.... engine out... suggestions? c5 rs6

[sempaipaul]

Alright, guys.

The RS has gone under a knife to rip out the turbos for a rebuild. The car went to my mechanic about 4 months ago for a strange idling issue. My guy tore it apart and found a busted check valve under the intake. We at that time also replaced the spark plugs, coilpacks, valve cover gaskets. He put it back together and there was an awful sound coming from the right turbo upon spool. The car was losing tremendous amounts of power. It was taken back apart, put back together again (as he thought it may have been a line to wastegate or something) but the same symptoms resumed.

He went ahead and dropped the engine. The following discovery was made in the drivers side turbo:


Needless to say appears as something got in there... however it doesn't seem as it went out the exhaust side:


The hope is that It bounced right on back out the intake tube through which it likely entered. We have looked everywhere... intake tube, manifold, intercoolers, and there is nothing to be found.

In any sense --- the engine is dropped and I am trying to get the most done as possible. The car has 86K miles and so far the list is as follows:
1. Full timing kit via the following --- although it was donr 20k miles ago... but since in there might as well?http://www.blauparts.com/proddetail.asp?prod=GH21132-1-C
2. Turbo rebuild via Scroll
3. Stern engine mounts
4. Apikol tranny mounts

Another item I wish I could get done is get the intercoolers tested and maybe modified for larger size if anyone is out there providing such service? I don't have the funds for wagners :(

Looking for advice on what else I should do while in there... the control arms and suspension were all done 5 months ago. Also the car already has the Bufkin metal tubes...

Here are some more pics of the drop:




Thanks,
Paul

[JTown77]

Did he drop a something in there?

[Kruat]

^^Ditto^^

I'd upgrade to wagner IC's and maybe De-Cat your DPs?

[Audibot]

Does ER make ICs for the RS6? Their website is horribly out of date.

Is your mechanic taking responsibility for destroying your turbo? And any reason not to upgrade the turbos?

While it is out, why not change the transmission fluid (if it hasn't been recently) and either rebuild it or upgrade the valve body with something from Level10? Can't hurt to have a sturdier transmission.

[mr_dave]

Does ER make ICs for the RS6?

Not sure, but the only ICs mentioned on rs6.com are Wagners.

And any reason not to upgrade the turbos?

If you're staying with the auto trans, just about the only turbos that will fit are OEM K04s since the trans is so huge. However, it is possible to upgrade the turbines in the stock housing.

[simonpoulton]

Check the ICs for leaks - you can bash up a test rig pretty easily and then dip them in water and check for bubbles. If they haven't been already fixed, there's a good chance they will look like a jacuzzi. Mine were hold no pressure and there was a tell tail oil stain near the bottoms.

[Audibot]

Not sure, but the only ICs mentioned on rs6.com are Wagners.



If you're staying with the auto trans, just about the only turbos that will fit are OEM K04s since the trans is so huge. However, it is possible to upgrade the turbines in the stock housing.

Thanks. I'm new to the C5 platform, so what's available, etc, is new to me.

[sempaipaul]

Did he drop a something in there?

Seems like it...

^^Ditto^^

I'd upgrade to wagner IC's and maybe De-Cat your DPs?

At $1,600 for those, I'm not too excited... I did look at SRM (Silly Rabbit Motorsports) intercoolers which are more conservatively priced at $990.00; actually even attempted to call the guy - but got the voicemail.

Does ER make ICs for the RS6? Their website is horribly out of date.

Is your mechanic taking responsibility for destroying your turbo? And any reason not to upgrade the turbos?

While it is out, why not change the transmission fluid (if it hasn't been recently) and either rebuild it or upgrade the valve body with something from Level10? Can't hurt to have a sturdier transmission.

I called ER... they don't make them for the RS6. Mechanic is a good friend of mine. I assume we'll be working something out with him. I'd love to upgrade but, not so sure about dropping $3K+ on a set of new turbos. I inquired with Loba on their 660 turbo's and those are $3,600+. Also now found the Silly Rabbit Motorsport RS6 Hybrid units - however, I am curious as to what they're made from (parts genuine or not? core exchange?) and where they're made. Once again... I called SRM today but got their voicemail twice... Transmission had fluid flushed 10K miles ago and had an MTM torque converter installed. I'll look into the valvebody. Wonder how much that may run.

Check the ICs for leaks - you can bash up a test rig pretty easily and then dip them in water and check for bubbles. If they haven't been already fixed, there's a good chance they will look like a jacuzzi. Mine were hold no pressure and there was a tell tail oil stain near the bottoms.

My guy tested them and, apparently they don't leak. However - they did act as a filter to the metal shavings of whatever it was that came in contact with the compressor wheel. We looked in the intake manifold and didn't see any signs of any shavings or debris. That means the intercooler may have acted as a good filter. Not sure how "dense" the "packing material" is in the intercooler but maybe it saved me. Now, however I am concerned about making sure that everything is washed out of it. I wonder if washing it out or even sonic cleaning it would be enough....

Not sure, but the only ICs mentioned on rs6.com are Wagners.



If you're staying with the auto trans, just about the only turbos that will fit are OEM K04s since the trans is so huge. However, it is possible to upgrade the turbines in the stock housing.

Scroll no longer does the hybrid conversions apparently. not sure of who else except for the stuff I found on Silly Rabbit Motorsports.

[Audibot]

I'd love to upgrade but, not so sure about dropping $3K+ on a set of new turbos. I inquired with Loba on their 660 turbo's and those are $3,600+. Also now found the Silly Rabbit Motorsport RS6 Hybrid units - however, I am curious as to what they're made from (parts genuine or not? core exchange?) and where they're made. Once again... I called SRM today but got their voicemail twice... Transmission had fluid flushed 10K miles ago and had an MTM torque converter installed. I'll look into the valvebody. Wonder how much that may run.

What about the JHM RS6-RS turbos?

I know it says 2.7T, but maybe call them up and see if it would actually work for an RS6?

[sempaipaul]

What about the JHM RS6-RS turbos?

I know it says 2.7T, but maybe call them up and see if it would actually work for an RS6?

Actually sent JHM an email this evening. We'll see what they say..

[sempaipaul]

Well I got an email back from JHM and they don't have anything for me. Also, got a call back from SRM. Their turbos are made of Malaysian made cartridges and Chinese housings. The gent on the phone claimed they haven't had any issues with them in 4 years they have been producing them.... I of course have my slight doubts on that.

Paul

[V1nny]

no sense in bigger turbo's unless you upgrade transmission, just rebuild yours with original BW cartridges. Bigger turbo will not benefit you at all, if anything your daily driving experience will be worse. Definitely consider aftermarket intercoolers, stock RS6 are very prone to leaks, nearly impossible to weld, epoxy repairs do not last. SRM intercoolers are great, just write them email, they will respond sooner or later, ask them for matching silicone hoses and clamps too. Make sure you mention you looking for a real RS6 replacement/upgrade intercoolers, not "RS6 style" for stage 3 2.7t, you will get your core deposit back, once they receive your old parts.
If you need someone to rebuild turbo's, check this guy out: http://timsturbos.com/ He is somewhat local, in DC area. He rebuilt my K-04's about 3 years ago and upgraded bearings. He is one man business, but had ~$50K worth tools and balancing machine in his shop. As for downpipes, talk to Ray at www.raimotorsport.com. I would do downpipes, to extend new turbos life, any performance benefit would be useful too, as it would be faster spooling in low rpm range.