2001 Santorin 6-speed S4, 149000 miles, APR Bipipe, Forge DV's, 18" Flik wheels(225/40 on all four), clean interior, few cracks in the front bumper...runs(smokey), but needs new turbos(still using OEMs).

After struggling for the last week, I am strongly considering selling my car(no parting out). I cannot figure out how to remove the damn turbos without pulling the engine. Nearest Audi dealer is 346 miles away in Albuquerque and I'm tired of wasting the lift space in the shop. AllDataPro is not helping me either.
I've seen other posts on how to pull the engine(even printed it out), but still am not certain or clear on how to remove the turbos. I saw someone post how all they did was remove them from the front of the engine. I'm confused as hell.

If anyone wants to help, I will offer free unlimited dyno time on our AWDDynojet. Call me at 915.849.8888, ask for Sean. I have 7 days left of leave then its back to Iraq for 5 more months.

 

Hey man I'm the one that did the front turbo pull. I posted a rough write-up a while back. It's actually not too difficult with a lift.
As far as a basic writeup on the swap:
-remove headlights, bumper.
-disconnect radiator hoses, power steering lines (use hose block off pliers the steering fluid is like $25 a liter), disconnect A/C lines from condensor.
-there are two torx bolts up top on the front clip, and four on each side on the frame rails. remove these and the entire front clip will come loose. you also may need to remove headlight washer lines (I don't have them as I have a Reiger bumper).
-take the bolts out of the front axles and allow to hang loose, then tie back toward the rear of the car for clearance.
-Once the front end is off remove the intercoolers and intercooler piping the main inlet tubes are held on with o-rings and are very tight, don't be afraid to use a pry bar to pop off.
-You now have access to the turbos, remove the oil and coolant lines (I had a lift so this was much easier)
-unbolt the turbos from the manifolds and the manifolds from the heads.
-unbolt the heat shields and then the downpipes, unplug the front 02 sensors
-remove the manifolds through the front of the car (I had to pry on the driver side of the engine for clearance to get the manifold on that side)
- the pass side turbo will come out the front of the car from underneath.
-the driver side turbo will cone out from the bottom almost straight down (you can pull this without removing the manifold but it's much easier if you do)
-remove the oil drain and fill lines and clean
-re-install is the opposite of removal.
- also you will have access to do a timing belt, water pump, serp belt, etc. I reccommend doing while this far along.

-tools required- Metric ball-end allen socket set, 8mm and 6mm straight allen sockets, 10-spline socket driver set (to loosen the axles), metric socket set, prybar set, phillips and flat head screwdrivers, metric box end wrench set, etc.

-notes: my car has an aftermarket bumper with custom intercooler supports, I removed the A/C completely with my swap, I reinstalled with aftermarket manifolds which took alot more work to get into the car than the stock ones coming out. Tools required is to the best of my recollection as I had the help of a tech, a lift, and 8 master-techs tools available to me. I'll post anything else that comes to mind.

Let me know if you have any other questions.

 

Dont know anything about the turbos or how to pull them, but I thank you for your service to our country.....!

 

oh, I hear you. Post locally on every board & find some one who has done it. I would drop the engine. There seams to be less of a struggle doing it that way.

Purchase a Bentley manual!

 

hey thanks for the quick reply devil, i just have all of that stuff off already and i'm wondering if i'm missing something...the three allen bolts are just very difficult to get too from the top side...i'll give it a shot again this morning

thanks again to all that replied

 

Which allen bolts are you stuck on? The turbos to manifold? They are a pain in the *** the easiest way is with a MAC swivel allen head set. I used a big allen key and a piece of pipe to break loose one that was really tight.

vnv727 the install was done at the pepboys that I work for. Yes we can do this again, I know pepboys is not the first place you'd probably take your car, but we are one of the highest volume stores and also have techs that have been there for 15-20 year and are very good.

 

Mechanicsburg PA, its right outside of Harrisburg. After doing the pull twice (there's another guy that works there with a S4) labor comes out to about $450 plus fluids etc. Couple extra bucks if you want to do the timing belt while the front is off.

 

well, after a few days of grunting, grease, and some blood...I got the engine out

started here:


ended here:


I had no idea how small the stock K03's were. I laughed when I got them out. But oh well. It was a true PITA working on this, but I learned alot. I have decided to order a new long block from Audi, and a few other new parts. The car is an Ohio titled model that had 149,000 on the odo. In addition I will order the K04's when they are in stock again. Plans are for manifold back exhaust upgrades, ecu work, larger intercoolers, and some minor fuel/intake mods. Nothing else on the car is wrong or bad. Looks like the turbos have been leaking forever. There is oil seepage caked everywhere and the water lines looked like they leaked real bad too. The sub-frame will be redone with an anti-rust compound and repainted. Oh and some front control arms/tie rods need to be replaced. Other than that, nothing. Since there is corrosion on the starter, alternator, and a/c compressor, i'll replace those as I get to them.The engine bay will be cleaned, treated, and repainted.

Big project for me to do since I'm all the way back in Iraq again. But i'll enjoy planning this out.

Thanks DevilS4 for the help and info. By the way, the allen bolts were tough, but they cracked under a bit of pressure.

 

Glad to see you got them out. Good luck withthe project.

 

Haven't gotten any recent pictures yet, but I just heard that I will need a new flywheel and clutch soon. I was planning on it anywhay, but this just confirms it.

I have pre-ordered one of two engines left in the US, shop price has been extended to me and the guys back home. Should be seeing it by the first of May.

Bascially the engine will be new with everything else freshened up. I'll be home by the first week of August(for good), so I hope I can get this car back on the road shortly thereafter.

One other item...I emailed ATP Turbo in Fremont, CA and asked if and when they would have upgardes available for the 2.7, they said "possibly this summer", but thats not very reassuring. However, if I can swing it, I'll head out to Fremont after the car is finished in El Paso and visit my sisters. (One in Fremont the other in San Mateo. I'm fromSan Jose originally.) While there I can always go by ATP and see what they are working on. I saw AutoSpeed Performance and their GT25R project with external wastegates, and it got me thinking. But the east coast is a little further than I want to travel from the southwest.

I'll post regularly about the S4 and what I'm trying to build up from over here. Have a great weekend folks!