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A7 BiTDI Turbo failure

Eric_BiTDI Aug 4, 2020

  1. Eric_BiTDI

    Eric_BiTDI A7 S Line BiTDI

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    Hi guys, recently purchased a '12 plate A7 BiTDI due to needing a big comfy auto but with a bit of power and I have always liked the look of the A7 so jumped in. I did have a friend who I have known for over a decade, and had trusted him with his previous work, put a generic flash map on it soon after I purchased it. This was the only power/engine modification that I had done.

    Fast forward five months and I hear a loud whine under acceleration (not the wife) and low ish power.. still drives okay with zero smoke or lights on the dash or DTCs stored.
    I like to tinker with cars and have about average knowledge so thought I would take a brief look for any obvious issues with the intake / turbo side of things.

    The airbox and intake pipe looked fine and no holes or damage, so I look into the turbo and see this...

    Turbo fail.jpg


    As you can imagine my heart sank.

    So.. I have had that map taken off, had two people out to check it.. both say different things. Personally I feel it has over-boosted and possibly fouled the inside of the housing, there is a bit of play in the shaft.

    I have explored a few options, Audi would like £4,850 JUST for the turbos. That is a no go.

    Company I got the A7 from say use the Warranty, but I've looked into it and long story short - useless.

    The only option for me is to pay myself. I have purchased a very low mileage second hand BiTDI turbo setup, all other gaskets I'd need from Audi too.

    I'll get this fitted by a professional, all checked over and also having a Wagner intercooler fitted too. Once this is sorted I'll be heading down to the Legendary BSR for a few power additions.

    I am not looking for diagnosis or being told off for generic maps, just sharing my experience so far!
     
    BD55SOL likes this.
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  3. rjwojcik

    rjwojcik Registered User

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    Bad luck bud.

    Do you think the map caused this? Could have been down to old age? How many miles and was it serviced well?
     
  4. Eric_BiTDI

    Eric_BiTDI A7 S Line BiTDI

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    Personally I think yes the map but as always, can never prove anything really. I don’t think it’s down to old age mate no, serviced well even transmission serviced too, 90k miles it’s done.
     
  5. RAF_S7

    RAF_S7 Well-Known Member Gold Supporter

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    For that much damage I’d say oil starvation or a failure upstream in the air intake side.

    I’d personally be very surprised if the map caused this, too much physical damage on the impeller tips.

    With that much metal missing from the impeller, you need to be careful that nothing has been ingested into the engine and caused/could cause further internal damage :concern:
     
  6. Eric_BiTDI

    Eric_BiTDI A7 S Line BiTDI

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    I agree with you @RAF_S7 about possible failure diagnosis. There’s just no evidence of anything hitting it ... but it looks like it has?! just very hard to pin point the issue. It could be a variety of things.

    It’s all going to be stripped and checked for debris properly - hoping the intercooler has caught most of it.

    Good excuse for a Wagner and further tuning:whistle2:
     
  7. Gazwould

    Gazwould Registered User

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    Looks like debris in the induction did that .

    What air filter are you running ?
     
  8. Eric_BiTDI

    Eric_BiTDI A7 S Line BiTDI

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    agreed mate it does look like it - but the intake and airbox and air filter all checked and nothing is missing or broken off.
    Fully standard that side of things mate.
     
  9. Gazwould

    Gazwould Registered User

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    Stock filter , K&N etc ?
     
  10. Eric_BiTDI

    Eric_BiTDI A7 S Line BiTDI

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    Fully standard intake and filter mate. I did buy an aftermarket filter .. but decided against it in the end.
     
  11. Gazwould

    Gazwould Registered User

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    Cool , aftermarket don't filter well at all and will result with your type of compressor wheel damage.
     
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  13. Eric_BiTDI

    Eric_BiTDI A7 S Line BiTDI

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    Ah okay, I didn't know that. Yeah I looked at it and compared it to standard when I got the aftermarket filter out, it seemed a poor fit so chucked it back in the box.
     
  14. Gazwould

    Gazwould Registered User

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    I mean performance aftermarket filter K&N etc filter very badly for no or very little gain .
     
  15. Eric_BiTDI

    Eric_BiTDI A7 S Line BiTDI

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    Yeah I know a lot of people fit them for sound purposes only, but as i have the active exhaust that is enough for me (plus I have the Kufatec sound booster coming)
     
  16. Gazwould

    Gazwould Registered User

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    Drilling the airbox in appropriate places does the K&N sound .
     
    Eric_BiTDI likes this.
  17. bobby singh

    bobby singh BSR Gold Supporter VCDS Map User

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    Something has been sucked
    I've got a CDUC in at the moment for some hybrid work with full Audi history and the Audi box has a missing O ring.With only 60k on the clock the turbo is ruined.
    Im putting on a VZK hybrid so doesn't matter too much but goes to show all seals and O rings are there for a reason.

    Just check your turbo in take pipe for holes - plus clean out all the charge pipes and wash out the intercooler. You may find whatever got sucked in and caused all this damage.
     
  18. Eric_BiTDI

    Eric_BiTDI A7 S Line BiTDI

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    Hi @bobby singh, I'll re check the airbox / air filter again and see if i can find anything.

    All intake pipes will be checked and flushed out and just ordered the Wagner with you to replace the standard intercooler.
     

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