Turbocharger Shaft Break: Causes & Repair

Hello.

I have a small question.

My aunt drives a Golf IV TDI.

The car is 5 years old and has only 45,000 kilometers (approximately 28,000 miles) on the odometer. All inspections have been carried out at the authorized service center.
He recently had a problem where the engine wouldn't accelerate when he pressed the gas pedal.
In the workshop, everything possible was checked, including the mass airflow sensor. Then, during the test drive, the turbocharger shaft broke and scattered inside the engine, resulting in a complete engine failure.

'My question is, does anyone have experience with the lifespan of these axles, or are there any regulations from VW regarding such cases? Are there any precedents? Has anyone experienced something like this before?'
I had already read the survey, and it did provide some clarity, but the question is how could something like this happen? I almost rule out a sudden failure due to wear and tear. The only explanation for me is that it's a manufacturing defect, such as a flaw or other impurities in the material. Does anyone know more about this?

The workshop offered an engine replacement for €5000, of which the workshop was willing to cover €1800. What do you think of this offer?

It would be nice to hear something, thank you.

Best regards, Thomas.

Hi there,

I'm certainly no expert, but...
"I've never heard of a turbocharger shaft breaking and causing a complete engine failure."
2. If a VAG workshop voluntarily wants to give away 1800 EUR, something is definitely wrong.

I might have the car inspected by an independent expert, and then I'll talk to my lawyer (if I have legal insurance).

But maybe the experts will have something to say about it, to see if that's possible.

Greetings.
dieter

Anything is possible, and the charger housings are designed to be explosion-proof for a reason.
It's also possible that VAG messed something up. Proving it later will be difficult. Do the pieces of debris still exist? Is everything present in the engine compartment? Missing clamps on a turbocharger hose, for example, would be highly suspicious.

I'm certainly no expert, but...
'I've never heard of a turbocharger shaft breaking and causing a complete engine failure.'


'There are even pictures that have already been posted here...'

While it's not common for larger parts to be damaged by LLK (likely referring to a specific substance or process), even small amounts can damage valves and bearing surfaces.

CU Gremlin.

Hello Thomas,

"I experienced a similar issue, but at approximately 160,000 km (around 99,000 miles). In my case, the turbine shaft also broke under full load. This resulted in a significant amount of aluminum debris from the compressor wheel being scattered throughout the intake system. However, most of it was caught by the oil cooler. Only very small aluminum particles made it into the engine. I only had the turbocharger replaced, and that was it. I've driven 10,000 km (around 6,200 miles) since then without any problems."

According to my mechanic, there are usually no problems with the engine itself when the turbocharger fails.

Unfortunately, you haven't specified exactly what's broken on the engine, but I suspect that, as in my case, simply replacing the turbocharger (and thoroughly cleaning the intake manifolds and intercooler) might be enough. The cost, including installation, was 1,000 EUR for me.

Greetings.

Rupert Gschwendtner.