S6/S7/RS7/S8 4.0T turbo failure

[SleekS7]

This poll was created to consolidate information from recent threads about turbo failures. If YOU have experienced a turbo failure, please take the poll and post the year, model, mileage, when any of the items in the poll were completed and when your turbos failed, and if tuned.

I'm not able to add attachments for some reason, but here are the related TSBs.

21F2 service campaign - ECU software update and replacement of coolant lines and O-rings - campaign started mid 2017 and appear to be limited to pre-facelift 2013-2015 all 4.0T models.

TSB 2036167 - Coolant Pipe seepage on Turbocharger - only MY 2013 all 4.0T models, BUT the TSB i have is dated June 2015 so may not have included newer years. This TSB outlines replacing the coolant line O-rings and came out well before the 21F2 service campaign.

TSB 2044640 - Engine difficult to start, turbocharger damaged - MY 2013-2016 for all 4.0T models, TSB dated Nov 2017. This TSB covers replacing the failed turbos.

TSB 2034999 - Miscolored pipe on turbocharger - Since people have mentioned the driver side turbo being oily/dirty during swaps/failures. This TSB explains the condition is due to the crankcase breather only being connected to the driver side turbo (TSB shows it dirty/oil varnished, passenger side clean). TSB is informational only, no service required and considered normal.


On my car, I had the O-rings TSB completed then a few months later, the 21F2 service campaign was released and had that completed too, no turbo failure yet at 36K miles.

[ryanlada]

Does any one know or have the means to find out details behind the different turbo versions for the 4.0t? When I was researching a stage 3 upgrade for my S6, the parts counter guy made a point to say that the rs turbos he quoted we're the "latest revision". He couldn't tell me more but made me think that there must be a revision log somewhere with details on what changed and why.

[parkstr8]

Maybe post in the regular forum that this is over here - as a lot of peeps don't know this one exists yet...

[SleekS7]

Maybe post in the regular forum that this is over here - as a lot of peeps don't know this one exists yet...

It was posted in the regular forum on the same day this sub-forum was created and the admin moved it here. While it could get more exposure being back in the regular forum, I think this is the proper place for this post. I'll reply to the main forum failure threads to reference back here.

[Cris_OO7]

My 13 S6 was just flatbed to the dealer. I took my car in Sept 17’ to have the 21f1 done for leaking turbo lines. Got the car back 1 day later. Then I started noticing burning oil smell cold start or after warm up. Took it back in on March to get them chk which my car stayed for 51 days they replaced the whole lines and seals this time.3 days later smell burning oil again. Been driving the car on short local trips then this past weekend I went on a 60 mile trip to visit a friend. As soon as I got iff his exit first stop light car starded shaking like a misfire but no CEL when I got to his drive way car shutdown dies not able to maintain rpm unless I keep giving it gas . Im 95% sure its the turbos choking the engine .


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[Derek978]

Bone Stock 2013 with about 49k miles. Unfortunately, it is a couple of months out of warranty (of course).

I was driving with my son home from the office last week and the car started to idle rough at a stoplight. We drove the rest of the way home and the car stalled in our driveway and would not restart. I originally suspected a bad tank of gas as I had just filled up that morning (10-15 miles of driving). I had it transported to the local dealer on a flatbed.

The recall /TSB for cooling / o-rings was done 8/29/17.

Audi fixed under "goodwill".

[kpriv]

As a follow up to frenetic's post in the other thread, I'd be very curious to understand how many folks with blown turbos were using the factory recommended 10k oil change interval (and also if they were using audi care castrol oil). It would be audi's fault and not the owners given it is a mfr recommendation, but an interesting data point to see if there is any correlation.

[ichi d]

It seems like after the latest recall fix, the turbos have been blowing up. I'm picking up my new to me 13s6 at the end on the month and thus recall hasn't been performed yet. Should I keep driving the car without doing this update until Audi comes out with a new fix?

[biehniac]

On my car, I had the O-rings TSB completed then a few months later, the 21F2 service campaign was released and had that completed too, no turbo failure yet at 36K miles.

How much did this run you? I've got a 2013 S7 with almost 51k. Seeing a little seepage on the driver's side coolant line and have smelled slight burning. Taking it in this weekend to a local shop.

[s4nicetry]

How much did this run you? I've got a 2013 S7 with almost 51k. Seeing a little seepage on the driver's side coolant line and have smelled slight burning. Taking it in this weekend to a local shop.

It's a recall, they don't change those orings for everyone though. If you can visibly see and smell the leaking I'm pretty sure yours will be changed.

[biehniac]

It's a recall, they don't change those orings for everyone though. If you can visibly see and smell the leaking I'm pretty sure yours will be changed.

Weird thing is I can't find any recalls or advisories associated with my VIN.

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[biehniac]

21F2 service campaign - ECU software update and replacement of coolant lines and O-rings - campaign started mid 2017 and appear to be limited to pre-facelift 2013-2015 all 4.0T models.

Does anyone know if Audi covers the service campaigns? It's my understanding they'll take care of recalls, but I'm out of warranty and want to know what I'm in for when I get 21F2 done.

[s4nicetry]

Does anyone know if Audi covers the service campaigns? It's my understanding they'll take care of recalls, but I'm out of warranty and want to know what I'm in for when I get 21F2 done.

service campaign is a recall

[biehniac]

service campaign is a recall

Audi's website categorizes them separately. Regardless, are they covered out of warranty?

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[ichi d]

Audi's website categorizes them separately. Regardless, are they covered out of warranty?

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All recalls are covered outside of warranty and is free of charge.

[digdah]

Wait, so is this poll telling me that 100% of the failures occurred only after the dealership worked on the vehicles?

[atobias80]

14 with 23k on it. Changed oil every 10k. Dealer found metal in oil filter and said it was from the turbos. Waiting on replacements now from germany. Car is still under cpo.


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[Cam.CL.S7]

Wait, so is this poll telling me that 100% of the failures occurred only after the dealership worked on the vehicles?

Thats troubling...

[jcs4]

Weird thing is I can't find any recalls or advisories associated with my VIN.

Sent from my SM-G960U using Audizine mobile app

same with me...is there any way to plug in the vin to see whats covered? i only see recalls.

[SleekS7]

Wait, so is this poll telling me that 100% of the failures occurred only after the dealership worked on the vehicles?

Yeah, that was my suspicion and the purpose of this poll was to try and identify if either TSB or service campaign may contribute to the failures. Seeing as most failures have been reported after the service campaign was initiated, maybe there's a flaw in the new lines or the dealers aren't installing them correctly?

[Cam.CL.S7]

Yeah, that was my suspicion and the purpose of this poll was to try and identify if either TSB or service campaign may contribute to the failures. Seeing as most failures have been reported after the service campaign was initiated, maybe there's a flaw in the new lines or the dealers aren't installing them correctly?

or planned obsolescence....

[wnee911]

Just yesterday, my 2014 S6 had symptoms almost exactly the same as those mentioned by Derek978 in post #6. I have an appointment with the dealer on Monday, but the service advisor suspects that it might be a turbo failure. 35,000 mile service was performed by the dealer just a few hundred miles ago, except for the oil change and oil, engine air, & cabin air filter replacements which I did myself shortly before the 35K service. I don't think the car has had any modifications done to it.

[wnee911]

Service advisor at Audi dealer says one turbo has failed and both should be replaced. A very expensive repair for a car that's just 4 years old with about 36,000 miles on it! Next we need to have a conversation with the Audi rep to see if they'll cover it. New car warranty expired about 2 months ago.

[4Chio]

Trust me when I say this ... Work the system... audi will cover the entire thing

Service advisor at Audi dealer says one turbo has failed and both should be replaced. A very expensive repair for a car that's just 4 years old with about 36,000 miles on it! Next we need to have a conversation with the Audi rep to see if they'll cover it. New car warranty expired about 2 months ago.

[wnee911]

Audi ultimately covered about half of the originally quoted price. Both turbos were replaced. TSB 2044640 was cited in the work description. Service advisor recommended using Audi oil filters only, an Audi-approved oil (e.g. Mobil 1 0W40 Euro), and changing the oil every 6 months or 5000 miles, whichever comes first.

2014 S6

[groo]

I have a 2016 S6 Avant (UK 66 plate) with only 11k Miles on the odometer that is having both turbos replaced at the dealership under warranty. Symptoms matched what others have been reporting - on a long run it started idling roughly. When I stopped it was impossible to restart. When cold it would idle but started hunting as it warmed and then would die. I will update the survey when I get my report back from the dealership.

[15 Phantom S6]

Audi ultimately covered about half of the originally quoted price. Both turbos were replaced. TSB 2044640 was cited in the work description. Service advisor recommended using Audi oil filters only, an Audi-approved oil (e.g. Mobil 1 0W40 Euro), and changing the oil every 6 months or 5000 miles, whichever comes first.

2014 S6

Funny how they recommend changing the oil every 5000 miles, but they won't do that when they are footing the bill ie: Audicare...

[ntsantos]

Damn guys...I hope my car lasts for just 2 more weeks.

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[MadAboutCars]

5 year warranty now. Peace of mind...

[LinenMonkey6262]

Hello all,

Think I have posted this in the right place.

I have an S7 (4.0t) 65 plate (December 15) with 19k miles on clock.

Looking for some advice as I'm preparing myself for having it out with Audi due to turbo failure on my car.

Inital diagnosis (by an independent repair centre) shows that 1 turbo is completly goosed and the other is on the cusp of the same. The exact terminology was "Turbo issue on your car note impeller touching turbo casing due to bearing failure" with 3 images showing the fault (the images dont mean anything to me).

The car is less than 6 months out of warranty and cost 66k invoice price (I financed the vehicle), I have had both services completed on 12k and 17k miles. No issues with the car until now.

Coincidently 2 days before my car went kaput I started the Voluntary Termination...couldn't beleive it when I was sitting in my knackered car with the pickup company calling me to organise return. Litrally had my head in my hands!!

My car is with the official audi workshop now, they are going to diagnose it themselves either tomorrow or Monday and will come back to me with...well, the damage!

Any words of advice really appreciated. Surely this cant be normal for a car of this cost and calibre?!

Thanks

[wwhan]

I see you're from the UK.

We get a raw deal here, you might get something from Audi out of goodwill seeing as it's only just out of warranty and is low miles, but be prepared for a big bill. If both services were from Audi dealers you might have a strong case.

Mine went on my '13 and I got a pair of reconditioned turbos, and replaced all the pipes, o-rings and other associated parts. 5k miles later and it's still ok, but the fear of them going is always there. Trouble is, I don't know what to replace it with.

You could consider the remote turbo supply oil screen setup JHM is working on. The Oil screen is the issue, not the turbo.

[RAF_S7]

Hello all,

Think I have posted this in the right place.

I have an S7 (4.0t) 65 plate (December 15) with 19k miles on clock.

Looking for some advice as I'm preparing myself for having it out with Audi due to turbo failure on my car.

Inital diagnosis (by an independent repair centre) shows that 1 turbo is completly goosed and the other is on the cusp of the same. The exact terminology was "Turbo issue on your car note impeller touching turbo casing due to bearing failure" with 3 images showing the fault (the images dont mean anything to me).

The car is less than 6 months out of warranty and cost 66k invoice price (I financed the vehicle), I have had both services completed on 12k and 17k miles. No issues with the car until now.

Coincidently 2 days before my car went kaput I started the Voluntary Termination...couldn't beleive it when I was sitting in my knackered car with the pickup company calling me to organise return. Litrally had my head in my hands!!

My car is with the official audi workshop now, they are going to diagnose it themselves either tomorrow or Monday and will come back to me with...well, the damage!

Any words of advice really appreciated. Surely this cant be normal for a car of this cost and calibre?!

Thanks

That’s a low mileage to be have a turbo failure at!

Assuming full service history and given its only just out of warranty, you will hopefully get a goodwill contribution gesture from Audi.

This whole turbo failure issue seems to be pretty random, and spread across a number of years. I think yours is the lowest mileage failure I’ve seen yet, and only the 2nd one I’m aware of in the UK.

I’m in an early 2016 S7, so not far from your build date. Now at 42k with no issues (fingers crossed)

If Audi don’t play ball, the the cost is pretty high for an OEM repair. Going Stage 3 with RS7 turbos is more cost effective as there are a number of suppliers providing the kit.

Keep us posted with how you get on. Good luck

John.

[wwhan]

That’s a low mileage to be have a turbo failure at!

Assuming full service history and given its only just out of warranty, you will hopefully get a goodwill contribution gesture from Audi.

This whole turbo failure issue seems to be pretty random, and spread across a number of years. I think yours is the lowest mileage failure I’ve seen yet, and only the 2nd one I’m aware of in the UK.

I’m in an early 2016 S7, so not far from your build date. Now at 42k with no issues (fingers crossed)

If Audi don’t play ball, the the cost is pretty high for an OEM repair. Going Stage 3 with RS7 turbos is more cost effective as there are a number of suppliers providing the kit.

Keep us posted with how you get on. Good luck

John.

Except for this one: https://www.audizine.com/forum/showt...1#post13139207

"Sadly need to contribute to this thread on my dad's behalf. His turbos need to be replaced, and it looks like his car may be one of the first 2016s to experience the issue.

2016 RS7 Performance
18,XXX miles
100% stock, never tracked/abused"

[SleekS7]

I have an S7 (4.0t) 65 plate (December 15) with 19k miles on clock.

Sorry not familiar with UK designations, but does "65 plate (December 15)" mean you bought it in December 2015? If so, and assuming you aren't tuned or TD1'd, you should still be under the factory 4 year warranty, so force Audi to repair it for free. It's a fairly known issue now with a TSB. I know you said you're 6 months out of warranty, but just in case.

[B6AUDI]

2013 S8 with APR stage 2

Stage 2 @ 23K miles (been changing my oil every 4k miles since tune)
21F2 recall @ 25K miles
Today @ 29K miles

Turbos are still going strong. Fingers crossed.

[zx9eric]

Add another turbo failure:

2014 s7 APR Stage 2
Purchased at 73k did oil change immediately. Next oil change done at 80k per in car reminder. I then changed the reminder to 5k using VCDS.
Stage 2 at 75k turbo failure at 84k. (Time for CHRA and Stage 3)
The annoying part: The car was in the dealer for extended service on the Air Separator. They did their multi point inspection and offered to replace the oil line gaskets for cost of parts and the rear brakes I decided to do myself. I asked if they could access the Oil Check Valve as I knew that was a common problem. The response was "it is not easily accessible". I replied I thought the Valve was just below the oil separator to which I got no reply. That was on June 10th...exactly 1 month before the "catastrophic turbo failure" (as described by the service tech now working on this repair).
(I have never posted here before bare with me)
[IMG][/IMG][IMG][/IMG]

[daytona rs7]

^ that's a significant failure.

Theres been a few posts of people that had shrapnel end up in the engines..clogging oil ports and/or scoring cylinder walls. may want to inspect cylinders ( use a scope cam) and drop the oil pan for a cleaning.

[zx9eric]

Thank you. That is the plan along with checking for carbon build up and cleaning as well. Hope to have this car back on the road by the end of the month. In the mean time I am back in my 01 s4 avant with 274k (still running strong).

[Dasquade]

Add another turbo failure:

2014 s7 APR Stage 2
Purchased at 73k did oil change immediately. Next oil change done at 80k per in car reminder. I then changed the reminder to 5k using VCDS.
Stage 2 at 75k turbo failure at 84k. (Time for CHRA and Stage 3)
The annoying part: The car was in the dealer for extended service on the Air Separator. They did their multi point inspection and offered to replace the oil line gaskets for cost of parts and the rear brakes I decided to do myself. I asked if they could access the Oil Check Valve as I knew that was a common problem. The response was "it is not easily accessible". I replied I thought the Valve was just below the oil separator to which I got no reply. That was on June 10th...exactly 1 month before the "catastrophic turbo failure" (as described by the service tech now working on this repair).
(I have never posted here before bare with me)
[IMG][/IMG][IMG][/IMG]

Sorry to hear :(. Mind me asking, was the oil seperator replaced because it had failed or it was a preventive replacement?
Insane stupid your 'dealer/tech' sended you in the woods or not answering your oilscreen replacement question. They should of done it no questions asked!
*somehow still thinking oil seperator failure is an early sign of clothed oil screen and oil pressure buildup, unless i'm still mistaken regarding the link between each other...

[zx9eric]

Oil separator was replaced. It made a very loud squealing noise any time it was not under load. Interestingly, I had just received the extended warranty information in the mail. I do not know any relationship between the oil separator and oil screen.