Going to ask that everybody read from start to finish before replying:
Car is a 2018 Audi S5, manufacturing date was prior to the rocker arm revision date. So definitely prone to that failure to some extent.
53k miles, driven in Washington state most of its life, now resides in Southwest Ohio. Stage 2 tune through IE and all accompanying hardware for last 20k miles. I decided to make the jump to Stage 3 with a pure 750 over the weekend. Install went great. Shop did it for me as I don’t have most of my tools after moving across the country. Fired up the car, let it idle for about 15 minutes with the new turbo and everything sounded as it should.
Went to flash the stage 3 software for both the ECU and TCU. After starting the vehicle on stage 3, immediately a very loud banging noise came from the motor. I immediately shut the car off, looked at the engine bay with the shop the did the install, saw nothing amiss. Flashed the car back to stock as a precaution before eventually starting up the vehicle again.
There is now an inconsistent metal tapping like sound coming from the area of the HPFP. It is very loud, much louder than the typical rocker arm failure videos I see. Car had zero symptoms of a potential rocker arm failure prior to this as well, and as I stated ran just fine once starting the vehicle directly after install. No injectors, or the HPFP were touched during install. Purely a turbo swap here.
Reached out to IE and they confirmed my flashing history had no errors nor cause for concern. I am not blaming the flashing process in this happening, just pointing it out for the sake of laying out a timeline. Insane coincidence is all it is to me at the moment.
Here is what I have now, on the stock files:
https://imgur.com/xFQnqNn
https://imgur.com/a/xLf1TFk
The noise as you can hear in the 22 second video varies in tonality, and actually comes and goes when meddling with the area of the motor the sound is coming from. It is very loud, and does not seem cyclic or rhythmic like the rocker arm videos sound that I have seen.
Shop removed turbo again today to verify install went as it should: no missing parts, no missing tools, and nothing went down the exhaust valve. They’re putting the turbo back on now and will be looking for the exact spot the sound is coming from afterwards.
Pulled codes this morning, and have these:
P0300
P0302
P0363
Checking spark plugs as soon as we get a socket that fits. Ones the shop had were too thick and couldn’t get into where they needed. Hoping for the best here, if anyone has heard anything similar or has a good idea of where to look here directly for an issue, I would appreciate the insight. Just seems insane the crazy timing here for this to happen. I do not have a clue what could’ve even been touched or tampered with to cause these mechanical failures, or if I really just had some bad luck.
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