BKD 3rd turbo failure, HELP!!!

[jdrift]

I have a 2004 audi A3 with the BKD engine and heres my story so far

I originally had the first failure a year ago whereby the turbo split in have near the webbing on the compressor side and pumped all the oil into my cylinders causing a bent rod, Took it to a mechanic who diagnosed the failure but the RAC warranty guys said we filled the cylinder with oil ourselves and refused to pay after having a few inspections.

Sucks but got a new engine fitted, with a turbo and a new EGR valve which proceeds to fail also and got that fixed under warranty from the engine supplier.

A few months ago the turbo fails again as I started to hear a whining sound so I replaced the turbo.

The turbo fails again last week and I am at a loss now.

The last time I had a new intercooler, everything cleaned etc by a relative who works at audi but obviously this was done out of hours....

Haven't had it apart yet this time but what could it be? My mechanic suggested it could be the EGR shutting off or possibly overboosting causing too much stress on the turbo.

I remeber that when we replaced the first engine we had to reuse the original EGR valve as the new one was faulty which makes me think it may be related.

Can anyone help as changing turbos is very expensive as I am sure some of you may know.

sigh....

[rooch]

I am on my 4th turbo and 3rd engine and also bkd. Long story but cause of turbo failures was the turbo was getting oil but oil return was not working. Shame it took VW soooo long to find it...especially as one call to my usual garage got the right answer without even seeing the car...which I suggested to VW after the 1st turbo went..shame they ignored me until they checked it after 3rd one blew.

[phil miller]

if it was me id check the oil return, and oil feed pipes, if all seems well, i would check the oil return flow rate as if the feed is slow it will cause massive problems

[jdrift]

to be honest the turbo shattering isn't going to be caused by bad oil feed/drain as they will just seize the turbo. The were being shattered i.e into 2 pieces manifold one side and compressor seperate from the manifold.

Anyway long story short replaced with a new euro car parts turbo and also removed the EGR flap as we have done that on other turbo cars where they were destroying the turbo in a similar fashion (shattering housings).

so for those with turbos splitting/fracturing housings or in my case totally annihalation (sp) remove and blank off your EGR. Been over a year and a bit now.

[rooch]

Glad you got it sorted!