Misfire

[Joegib1983]

Nice one... that all sounds promising....!!

Lig.

Here’s hoping mate. Will find out in a couple of days.

[Tadass910]

24k miles and car old 4 years, were you driving it or just keeping in garage?

[Paulm]

It’s just turned 4 years old now. The misfire is not that bad and is not throwing up the engine management light. Hoping it’s just something like a dodgy plug or coil. I’ll hopefully have an idea mid afternoon if it shows anything on the diagnostics.

My missfire, rough idle and lack of power turned out to be one failed turbo (shaft broken) and the 2nd close behind (bearings goosed). No engine light either

So the garage has called me there as they have just started work on the car while waiting for the warranty company to approve the claim fully and it appears that I have exactly the same issue as you Paulm. One turbo shaft broken and the other it’s pretty close to failure going by the amount of play in the shaft. Absolutely shocking for a car that’s just 4 years old with 25k on the clock. Hopefully hear back from the warranty company in the next few days but half tempted just to reject the car as I only had it a matter of weeks “working”.

AHH, that's <beep>. It's such a subtle failure it feels insignificant until you start to strip it down. Hope the warranty covers it. Big bill if you go OEM parts. Only cost me £500 with my Chinese turbos but I do everything myself

[Golfather]

From the zine:


The Situation:

There have been several members on here who have conducted all the preventative maintenance with regard to their oiling system, and still experienced turbo failures.

I sent some photos of their compressor wheels over to a friend of mine who has worked at Honeywell specifically analyzing turbocharger destructive testing.

The Findings:

Upon examination of the damaged compressor wheel he determined that these failures are the result of “Low cycle fatigue failure.”

Low cycle fatigue failure is the result of material failure of the cast compressor wheel from the stresses of rapid acceleration and deceleration.

As the compressor wheel rapidly accelerates from low speed to high speed, small cracks develop in the material of the compressor wheel.

These stresses are exasperated by over-speeding the compressor wheel when the vehicle has aftermarket software in order to increase boost pressure to achieve higher horsepower outputs.

These small cracks grow over time and eventually the compressor wheel comes apart under acceleration or deceleration.

His quote:

“It’s pretty shitty that the factory didn’t get this right, this is a design flaw from the factory. It’s really easy to test for this.”

The Remedy:

Utilizing a billet compressor wheel will dramatically improve the strength of the compressor wheel, and at a minimum significantly reduce and/or potentially eliminate the possibility of Low Cycle Fatigue failure on these turbos.

Notes:

This is not to say that the oiling system is not a problem. If the screen is not removed, replaced, or an aftermarket solution installed. Any turbocharger WILL still fail due to a lack of oil supply from a clogged screen.

1) Make sure you take care of your oil system to ensure adequate flow of oil from the engine to the turbocharger.

2) Replace your center section with a cartridge with a billet wheel.

Ensuring the two things listed above are taken care of, and, you are on a stock tune, this should completely eliminate turbo failure issues on these cars.

If you are on an aftermarket tune, and do these two things, it should minimize, and potentially eliminate your chances of turbocharger failure. The chances of turbocharger failure are always there when running turbos at or beyond their designed operational limits.

Hope this information helps some of you out.

[Joegib1983]

24k miles and car old 4 years, were you driving it or just keeping in garage?

Only had it a couple of months

[Joegib1983]

From the zine:


The Situation:

There have been several members on here who have conducted all the preventative maintenance with regard to their oiling system, and still experienced turbo failures.

I sent some photos of their compressor wheels over to a friend of mine who has worked at Honeywell specifically analyzing turbocharger destructive testing.

The Findings:

Upon examination of the damaged compressor wheel he determined that these failures are the result of “Low cycle fatigue failure.”

Low cycle fatigue failure is the result of material failure of the cast compressor wheel from the stresses of rapid acceleration and deceleration.

As the compressor wheel rapidly accelerates from low speed to high speed, small cracks develop in the material of the compressor wheel.

These stresses are exasperated by over-speeding the compressor wheel when the vehicle has aftermarket software in order to increase boost pressure to achieve higher horsepower outputs.

These small cracks grow over time and eventually the compressor wheel comes apart under acceleration or deceleration.

His quote:

“It’s pretty shitty that the factory didn’t get this right, this is a design flaw from the factory. It’s really easy to test for this.”

The Remedy:

Utilizing a billet compressor wheel will dramatically improve the strength of the compressor wheel, and at a minimum significantly reduce and/or potentially eliminate the possibility of Low Cycle Fatigue failure on these turbos.

Notes:

This is not to say that the oiling system is not a problem. If the screen is not removed, replaced, or an aftermarket solution installed. Any turbocharger WILL still fail due to a lack of oil supply from a clogged screen.

1) Make sure you take care of your oil system to ensure adequate flow of oil from the engine to the turbocharger.

2) Replace your center section with a cartridge with a billet wheel.

Ensuring the two things listed above are taken care of, and, you are on a stock tune, this should completely eliminate turbo failure issues on these cars.

If you are on an aftermarket tune, and do these two things, it should minimize, and potentially eliminate your chances of turbocharger failure. The chances of turbocharger failure are always there when running turbos at or beyond their designed operational limits.

Hope this information helps some of you out.

Cheers for the reply golfather. Good breakdown of the findings there. Now that this has happened to my car it’s frightening the amount of people this has happened to through a bit of research. Seems more and more common.

I will hopefully find out what the outcome is tomorrow with the warranty company as they have yet to reply. If they pay for the full repair I was already contemplating changing to billet compressor wheels and paying the extra. Turbo oil screen is getting replaced already as I asked the garage to do this when they were changing the PCV.

[gikseiman]

From the zine:


The Situation:

There have been several members on here who have conducted all the preventative maintenance with regard to their oiling system, and still experienced turbo failures.

I sent some photos of their compressor wheels over to a friend of mine who has worked at Honeywell specifically analyzing turbocharger destructive testing.

The Findings:

Upon examination of the damaged compressor wheel he determined that these failures are the result of “Low cycle fatigue failure.”

Low cycle fatigue failure is the result of material failure of the cast compressor wheel from the stresses of rapid acceleration and deceleration.

As the compressor wheel rapidly accelerates from low speed to high speed, small cracks develop in the material of the compressor wheel.

These stresses are exasperated by over-speeding the compressor wheel when the vehicle has aftermarket software in order to increase boost pressure to achieve higher horsepower outputs.

These small cracks grow over time and eventually the compressor wheel comes apart under acceleration or deceleration.

His quote:

“It’s pretty shitty that the factory didn’t get this right, this is a design flaw from the factory. It’s really easy to test for this.”

The Remedy:

Utilizing a billet compressor wheel will dramatically improve the strength of the compressor wheel, and at a minimum significantly reduce and/or potentially eliminate the possibility of Low Cycle Fatigue failure on these turbos.

Notes:

This is not to say that the oiling system is not a problem. If the screen is not removed, replaced, or an aftermarket solution installed. Any turbocharger WILL still fail due to a lack of oil supply from a clogged screen.

1) Make sure you take care of your oil system to ensure adequate flow of oil from the engine to the turbocharger.

2) Replace your center section with a cartridge with a billet wheel.

Ensuring the two things listed above are taken care of, and, you are on a stock tune, this should completely eliminate turbo failure issues on these cars.

If you are on an aftermarket tune, and do these two things, it should minimize, and potentially eliminate your chances of turbocharger failure. The chances of turbocharger failure are always there when running turbos at or beyond their designed operational limits.

Hope this information helps some of you out.

Cheers for the reply golfather. Good breakdown of the findings there. Now that this has happened to my car it’s frightening the amount of people this has happened to through a bit of research. Seems more and more common.

I will hopefully find out what the outcome is tomorrow with the warranty company as they have yet to reply. If they pay for the full repair I was already contemplating changing to billet compressor wheels and paying the extra. Turbo oil screen is getting replaced already as I asked the garage to do this when they were changing the PCV.

What was the end result of this? Did you get the vehicle repaired and is it performing as it should now?

[Joegib1983]

Will be getting it back mid November when I’m back from offshore. Had a nightmare fight with the warranty cover but eventually they have agreed to pay out approx 80% of the total claim. Been a fight backwards and forwards to get them to agree as they only wanted to pay out for the 2 turbo units (no seals, studs, gaskets, filters, oil etc). I’ll update once I get it back.

[Joegib1983]

Got the car back thismorning and it’s running like a dream so far. Long may it last this time. Much different to drive from when I first picked it up. Power delivery is so much improved and much sharper on full boost. Would recommend A for Audi in Glasgow to anyone that’s having issues with their car. Very professional service and their knowledge is second to none. Especially on high performance Audi’s. Very impressed!

[Tadass910]

So if you even not expecting any issues you should ask Audi dealer to check turbos and oil strainer? Will they agree to look if there is no codes nothing?

[Joegib1983]

So if you even not expecting any issues you should ask Audi dealer to check turbos and oil strainer? Will they agree to look if there is no codes nothing?

Probably not knowing main dealers. From my experience main dealers won’t do anything that they see as “unnecessary”