Audi RS2 Turbo whine/failure

[Golfboy666GTI]

Last December I had the head on my RS2 freshened up. While it was off I though it would be a good opportunity to rebuild the turbo (2 birds one stone).
Anyway the turbo guy said that the turbo was fine but they rebuilt it anyway. For a the month or so with the radio off I have heard a faint whistle from the exhaust. This got worse last week (as can been heard in my crappy video):

http://www.youtube.com/watch?v=mQLuIPccEIA

The turbo came off today, this is the damage:



Any idea whats gone wrong? The wheel/impeller doesnt move up or down at all and it moves forward and back about 1mm.

What do you think has happened?

Also, since I got the car back 6 months ago it only boosts to 17PSI where beforehand the boost gauge showed 21PSI (the car is factory standard).

[rynaqui]

I'm no turbo expert but doesn't look like it was lined up properly at all.

[UrS4boy]

I'm no turbo expert but doesn't look like it was lined up properly at all.

I presume a rebuilt involves new journal bearings. If so, how can you screw-up the alignment of the shafts relative to the housings and end up with blades touching the housing unless the shaft has significant where and/or the oil lines weren't working and the shaft wore after the rebuild?

Here is twoqu's (Robin's) RS2 turbo disassembly procedure that I consolidated (posted previously):

http://12v.org/urs/RS2%20Turbo%20Disassembly%20by%20twoqu.pdf

[stocious]

looks like its compressor is sitting too deep in the housing, maybe thrust bearing, you say it moves in and out alot ? good save with removing it for look, glitter coated intake is no good..

not a turbo guru either but wouldnt there be witness marks of balancing, on the nose/nut ect.

hope you get your answer

[rynaqui]

I presume a rebuilt involves new journal bearings. If so, how can you screw-up the alignment of the shafts relative to the housings and end up with blades touching the housing unless the shaft has significant where and/or the oil lines weren't working and the shaft wore after the rebuild?

Here is twoqu's (Robin's) RS2 turbo disassembly procedure that I consolidated (posted previously):

http://12v.org/urs/RS2%20Turbo%20Dis...by%20twoqu.pdf

I don't know

At least no damage was done to the engine..

[prj]

If it moves forward and back 1mm the turbo is done with.
You need a new compressor wheel and a full rebuild.

[Pat D]

As prj said, forward and back movement should be close to nothing. Correct me if I'm wrong, but there is normally a little movement up and down which would allow for an oil clearance in the journal bearing.

If you had no lubricating issues that would cause that damage, I would take it back to them, throw it on their desk and tell em to fix it.

[Golfboy666GTI]

As prj said, forward and back movement should be close to nothing. Correct me if I'm wrong, but there is normally a little movement up and down which would allow for an oil clearance in the journal bearing.

If you had no lubricating issues that would cause that damage, I would take it back to them, throw it on their desk and tell em to fix it.

How would I know if I have had any lubricating issues? The car never runs low on oil.

[prj]

My advice is, stop posting and start doing.
Most likely the turbo shop is at fault here, if it started doing this right away.
Either that or whoever fitted it to the car dropped it or similar.

Regardless, the cause of failure will be evident once the turbo is disassembled.
If you do not trust the current shop, have an independent shop do the teardown and analysis. Do NOT drive the car.

[Pat D]

For a lubricating issue it would be something extreme and obvious like a kinked hose/restriction, or contaminated oil and you'd still have to be un-lucky for something to happen so quick. If it wasn't right from the start after the rebuild, then the rebuilder would've been the cause of it.

[220bhp]

This happened to my brand new rs2 turbo running to much uncontrolled boost because of some bad mapping. Had it rebuilt by CR turbos, they where brilliant.
How much where you charged for the rebuild, because it is very expensive to rebuild an rs2 turbo.

[Rusty]

Get a billet hybrid rs2 from the US.

[UrS4boy]

looks like its compressor is sitting too deep in the housing, maybe thrust bearing, you say it moves in and out alot?

No or improper thrust bearing would be one answer. Item 10 in the diagram.

RS2 Turbo Parts Catalogue: http://12v.org/urs/RS2%20Turbo%20Parts%20Catalog.pdf

[Golfboy666GTI]

I took the guy who rebuilt the turbo for a ride around the block to confirm that the turbo was indeed damaged. He accused me of turning the car off straight after a high speed run with no cool down time. This is something I would never do.

[prj]

I took the guy who rebuilt the turbo for a ride around the block to confirm that the turbo was indeed damaged. He accused me of turning the car off straight after a high speed run with no cool down time. This is something I would never do.

********.

1) The turbo is water-cooled.
2) The car is fitted with an after run pump. Even if you do this, it's not going to cause serious damage. Yes, in the long run it might not be beneficial, but we are talking YEARS here, not a few months.

Do you have any receipts for anything? Sounds like you need a lawyer at this point.