Well for about 4 months my wastegate has been rattling when decelerating or when the throttle is goosed at idle. I thought it was some other exhaust rattle (like the cat heat shield) up until last weekend when I went looking for the source and found that it was the turbo. I checked the wastegate actuator and it seems fine. So now I need to replace the exhaust side of my K04. Luckily I have my old K03 on the shelf that will serve as the exhaust side donor. The probelm isn't affecting perfromance yet but the rattling is really starting to annoy the hell out of me becuase it is getting pretty loud.

So, has anyone taken apart a K03 or K04? Does the exhaust side come off easily or are there a bunch of seals and retaining rings that make it a PITA? I'm trying to figure out how much time I need to allow for this project and figure out if there are any misc parts that I need to buy. From the diagrams that I have found, it should be a piece of cake to switch the exhaust sides over but I just want to make sure before I go ripping into each turbo and screwing them both up.

 

I dont think the bentley manual breaks down the turbo peice by peice but ill check in a couple hours when i get home if no one has helped you by then.
Only because your Audi is Silver.

 

I got the bentley manual at home too and didn't see anything---however that things isn't the easiest manual to find stuff in. The best diagram I found so far was one that showed all the parts for a rebuild kit.

 

Yeah i think its even worse trying to find things on the cd version. Took me 10 mins to find a diagram of the air box.

 

that's a common problem with heat shields one they don't work two they rot like hell, look into exhaust bandage

http://images.google.co.uk/imgres?im...l%3Den%26lr%3D

then remove the tacky heat shields

 

yes to silver audis that the best color

 

once you get the turbo out its really not that hard to pull apart man

 

I can't get the bolts free that hold the exhaust side on. I've been applying penetrating oil daily for about 10 days. They still won't budge.

Does any body know of a good open end wrench that will grab the sides of a nut. Craftsman has the Extreme Grip but it doesn't come in 10MM and the bolts have a 10MM head. A box ends won't fit because they are too fat. I may just get a good box end and grind it down so that it will fit but if anyone knows of good open end wrench let me know.

I have looked at the Mac Tools, Snap-On, Kobalt, Sears and Harbor Freight websites and haven't found anything. Anybody got any other suggestions?

 

I had to use Liquid wrench on mine when removing my K03. Get some liquid that can either losen the botls or help with rust. Either that or try that better wrench like you were thinking

 

Pb blaster.