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....