So my new turbo (k04) comes in tomorrow and I wanted to get a head start on it tonight by getting the k03 out.

Im following the instructions from audi diy to try and make sure I do it all right. http://www.audiworld.com/tech/eng27b.shtml

Ive worked on cars for quite a while so I know what im doing in general but there are a few small questions I have.

First: I got the cat to turbo bolt off pretty easily along with all the exhaust mani to turbo bolts. I cant however get to the bottom or far turbo cat bolts, whether it be with a socket and an extension plus crow extention or a 17 wrench.

Second: the only wrench I can get to the turbo mount bolt with is seeing to not fit very well, and I cant turn it enough to put pressure on it to get it out due to it being too long. Any help on that either?


After that im assuming I need to get the oil drain on the bottom of the turbo, but I figure I can do that when underneath the car with the turbo loose.

This is all just driving me crazy. Ive been at it all night, and to no avail. I can put some pictures up in the morning to further illustrate my problem. thanks for any help.

 

pics would help

 

To do the turbo, consider the following stuff a requirement:
-A set of gear wrenches
-A stubby gear wrench sized for the turbo-cat bolts (forget what size)
-A set of "obstruction wrenches" - I have these: http://www.harborfreight.com/cpi/cta...emnumber=99564 - alternatively, S curved wrenches might work as well: http://www.harborfreight.com/cpi/cta...emnumber=99699

 

-Going in from the wheel well is easier on the cat bolts, but i managed to get em out without having to do that... is your cat welded on the back side? If not, unbolt it there and wiggle the turbo and cat out in one piece. (This is easier on some a4's than others for some reason.)
-Turbo bracket mount was an allen i thought (havent had a stock turbo setup in awhile sorry)
-Also have you tried accessing this stuff from underneath the car?
-Make sure you didnt break any of the manifold-turbo bolts off inside the turbo housing. Its somewhat easy to think you just got the bolt loose, when actually you snapped it in half. If you did, buy new bolts.
-Also make sure you pull your fuel pump fuse and crank the engine for like 5-10 seconds when the new turbo is in to cycle some oil through it before actually starting the car.

 

when i did mine i replaced the cat with a test pipe so i just cut my cat off i can't help ou there with the oil return you have to take it off of the oil pan and somehoe wiggle it up through the engine bay. and yeah the turbo mount bolt is an allen i think it was like a 7mm. good luck with that it gets so hot and cools everytime you drive it so its pretty well stuck in there. i cut mine out and replace it with a new one. just an idea. not the right way but it worked.

 

Just got the ity bitty k03 out, and now I know why I wasnt boosting. Along with the fact the turbo had immnse shaft play and blown oil seals, something seems to be missing here...


In car

Almost out


Hmmm. Where did it go?

There it is.

 

Thats seems to be very common that the wastegate blows off/apart. But hey props to a4's for getting into the 13's with a turbo the size of an actual snail.

 

So at this point in the installation ive come to realize I didnt get studs to put in the new turbo and I cant seem to get the old ones out.

Are they something I can grab at autozone, or is it like a order at dealer and wait a week for part?

 

You want studs to install your turbo for you? Try craigslist under adult services LOL

No but seriously what studs are you talking about? Everything looks good in your pics. You can use the same manifold-turbo bolts as long as they arent broken, and the k04 should have studs sticking off the hot side to go to the cat just like your k03... so what do you mean?

 

Haha, Well no, I mean the new turbo didnt come with studs on the hot side. And I cant seem to pull the old ones out without stripping them.

But For all my other stud needs I will consult craigslist from now on.