Audi Turbo Replacement

[Copecetic]

Hey guys!

Long time lurker, first time poster. I've been doing a lot of research on my situation so I'll try not to be "that guy" asking easily answered questions.

I recently purchased a 2012 Audi A4 quat. I absolutely love the car and got it with only 39k miles on it!

The bad part

The car ran well for a few weeks until I started getting an "under boost" code After pressure testing my intake system today (thanks to this forum's guide ) I'm pretty sure I have a bad wastegate.

Unfortunately I've been going through some of the usual problems like replacing the D.V. and getting a new P.C.V. I've owned turbo vehicles in the past and enjoy working on them so this isn't a big deal to me. The under boost code seems to be a bigger issue.

The boost comes and goes especially at low rpm's. I've watched a few Youtube vids on how to diagnose a bad wastegate and this seems to be the case.

TL;DR
Bought 2012 a4, fixed usual known issues/pressure tested intake but still getting under boost code. Bad wastegate?

The good part

A close friend has his own auto shop and will let me into a bay to freely use a lift/tools. I'm pretty comfortable with a wrench and plan to go about tackling the turbo replacement myself with some of his help. However he has his own paying customers to take care of and I will mostly be on my own.

I've been googling and searching a few Audi forums and haven't found a comprehensive guide to replacing the turbo on this model with the 2.0. Lot's of 1.8 information out there though lol.

This guide : http://www.audizine.com/forum/showth...4-Installation doesn't have any working pictures, while the instructions are still there it's not written to be followed without illustration and isn't great help.

I've also checked the DIY-Diagnose-and-Repair-of-Loose-Wastegate-Flapper-(P0299) guide.

I've had very little luck finding updated information on going about this. I would even be happy to document and write up a quick guide for others to follow if needed. Does anyone know of a good B8 turbo replacement guide?

All the information I seem to find regards older models and turbos for the 1.8T. Is there any reason not to just upgrade to the stock ko4 or keep the stock ko3? Are these turbos even reliable?

Any help in this endeavor is appreciated, I know it's a PITA but I'm excited to tackle a new project car. I plan to apr stage 1 first thing after replacement. However, are there any "essential" upgrades that should be done while I have it everything apart? Anything restricting? I'm trying to avoid loud exhaust notes

I'm sure I'm asking a lot of really rookie questions here, I've been googling my fingers off for a few days now. The job doesn't look too hard at a glance and I'm excited to finally have a project car again.

Appreciate any help anyone can offer!
TL;DR
I want to replace turbo with stock ko3 or ko4 but cannot find a guide with working pictures.

[lettuce]

Photobucket, wow what a shithole. I believe you can still view all those pictures where they're hosted here:

http://s1112.photobucket.com/user/dq...?sort=3&page=1

But you'll have to provide the context yourself. Better than nothing.

Maybe someone can ping @Dan_Q or reupload them all to imgur and repost them.

[Fastbke170]

I just replaced my k03, with a Franken turbo 2 weeks ago using just front ramps. So having a lift might make it easier In some ways. If your friend has strange tools to work on German cars that will be a plus as well. I and a few others on here learn from each other and as each lesson is learned the next person will benefit. I'm my opinion you do not need to drop your down pipe nor do you need to remove the cat. It's not easy but all nuts on cat/Exh manifold flange can be accessed with wobble extensions or a swivel ratcheting head. My biggest headache should have been the easiest step removing heat flange over turbo. I didn't heed the warning and stripped a bolt very close to each manifold runner. Also make sure you order all the gaskets, ECS tuning has a kit but it Does Not have everything. Invest in OTC shorty triple squares. They saved my life. After the Turbo was mounted I needed to adjust (bend) an in board oil line which loosened it. Had it not been for having the correct tools I would have never been able to access it. The last Tip I would give is after you remove the turbo. The metal fixed lines have flat securing tabs that not only keep the lines together. They also mount to engine. I used a dremel to cut them all off, it will save you huge headaches remounting them and CTS Turbo recommend removing them as well. They also have a good guide, just ignore the DV relocation part. Nothing ever goes prefect to plan, take deep breathes plan ahead don't rush and you'll be fine. Its just now 3 weeks later I'm actually enjoying the car. All I'll say is you decide to go with Franken turbo and Eurocode is your software, Choose F23LV2 AG revision ECM (2012) FILE. good luck.

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[hpmurdarah]

If ur already comfortable, just do it, take ur time, don't panic and remember what comes off must go on, replacing a turbo is easy, u should think of any upgrades u wanna do now in regards to your turbo!!

galaxy s7

[Dr. Awesome]

I'm not sure if the symptoms are all consistent with this, but if it is just the wastegate actuator you can do it without much effort. Check out this DIY, it will help you diagnose and repair for cheap if that is it.

http://www.audizine.com/forum/showth...nose+wastegate

[Copecetic]

Sorry i've been out of town and unable to reply until tonight, Thank you all so much for the helpful responses. Happy fourth!

Photobucket, wow what a shithole. I believe you can still view all those pictures where they're hosted here:

http://s1112.photobucket.com/user/dq...?sort=3&page=1

But you'll have to provide the context yourself. Better than nothing.

Maybe someone can ping @Dan_Q or reupload them all to imgur and repost them.

You know, that's actually helped a lot. I can make sense of most of it visually. I really just wanted to make sure I was taking everything off in the proper order I should be able to reassemble afterwards.

If ur already comfortable, just do it, take ur time, don't panic and remember what comes off must go on, replacing a turbo is easy, u should think of any upgrades u wanna do now in regards to your turbo!!

galaxy s7

Thanks for the words of encouragement. I'm pretty excited about it and plan to knock it out as soon as I can locate a suitable turbo. Keeping in mind that I would like to keep the exhaust sound as quiet as possible and I don't plan on going past a stage 1/2 apr tune. Is there anything you would recommend to upgrade? I'm also trying to shop a reliable ko3 or ko4 turbo to keep up with the 16-17 lbs for the tune. It seems ECS has a pretty decent looking kit.

I'm not sure if the symptoms are all consistent with this, but if it is just the wastegate actuator you can do it without much effort. Check out this DIY, it will help you diagnose and repair for cheap if that is it.

http://www.audizine.com/forum/showth...nose+wastegate

Unfortunately that's a post I linked in the OP that has no working images to go with the instructions. While I'm pretty familiar with "wiggling" the wastegate arm to see if the flapper is loose I don't think it conclusive enough on it's own. I have pressure tested my intake system and have found no leaks. I still get on/off boost surges especially in low rpms and my engine code keeps coming back "boost under pressure".

If you can think of anything else aside from pcv/Dv that would cause these types of issues I'd love to give it a try before dropping so much money on something that may not be broken :)

[Nano909]

Or you can call your local Audi dealer and setup an appointment to get a free turbo installed. All you have to do is have your CEL with the underboost code on and go in. The turbo has warranty for all owners even if you weren't the original owner. Warranty lasts until 70k miles on the clock. So call asap.

[LionKing]

Also you could replace the wastegate actuator with a nice aftermarket FORGE one, set it to a good tightness, run a boost log with a VAGCOM and adjust from there 😉

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[Copecetic]

- - - Updated - - -

Or you can call your local Audi dealer and setup an appointment to get a free turbo installed. All you have to do is have your CEL with the underboost code on and go in. The turbo has warranty for all owners even if you weren't the original owner. Warranty lasts until 70k miles on the clock. So call asap.

My car is a salvaged title. According to Audi it doesn't fall under the extended warranty for the turbo.

If the salvaged title doesn't disqualify it though I will go back and try again!

- - - Updated - - -

Also you could replace the wastegate actuator with a nice aftermarket FORGE one, set it to a good tightness, run a boost log with a VAGCOM and adjust from there 😉

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Youre suggesting using a stronger wastegate actuator to "hold" the wastegate tighter to the turbo?

[Nano909]

[QUOTE=Copecetic;12528455]- - - Updated - - -



My car is a salvaged title. According to Audi it doesn't fall under the extended warranty for the turbo.

If the salvaged title doesn't disqualify it though I will go back and try again!

- - - Updated - - -


I don't think I've ever heard of car history affecting the turbo warranty. If you heard it from Dan from down the street, then I'd suggest calling the dealer and make sure of it. Unless your car is flagged TD1, then the extended warranty should still be in effect.

[LionKing]

- - - Updated - - -



My car is a salvaged title. According to Audi it doesn't fall under the extended warranty for the turbo.

If the salvaged title doesn't disqualify it though I will go back and try again!

- - - Updated - - -



Youre suggesting using a stronger wastegate actuator to "hold" the wastegate tighter to the turbo?

Correctamundo. I did the replacement on mine. No code and I can actually feel boost now. Cheaper than buying a turbo. Just make sure you either have a VAGCOM to do a boost log to adjust it correctly or while you have the cat off, feel the wastegate to where it's just tight and give it one more turn until you can read your numbers. Sorry was on vacation.

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[LionKing]

I understand it says it's not for our vehicles but this is the correct part and the part I used. The one they have listed for our vehicles will not work. https://www.ecstuning.com/b-forge-pa...fmacvag08~frg/

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[tnpb21]

FYI....Bout my 2011 B8 in 12/18 with 65k on her, P0299 popped up...then popped up again .. then I heard the ticking...used forums to do research and now at 82k my appointment for replacement is set for next Wednesday. Using these forums, I popped around, learned some cool ish, and have a Forged actuator on the way which should be here just in time for me to have them put it in!!!


Much thanks Forum Family!!! Will report back once she's been tended to!

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[cuda2000]

DIY Turbo Replacement Video link below
My 2010 A4 Quattro with 86k miles, which I have owned since brand new, had a faulty wastegate and p0299 code.
So, I replaced the turbo and added an Ebay test pipe last week and I made a DIY video. Will go with Stage 2 Unitronic in a couple months.
The video starts out diagnosing the problem, then I go through step by step how to do the install.
Enjoy!
https://youtu.be/bW70AlIyof8Replace turbo audi a4 a5 q5 2010 2015 k03.jpg