B8 A4 DIY: K04 Installation

[PaulThBrit]

This is a great thread. Thanks for taking the time to put it together and embedding all the pictures. I am replacing the turbo on my 2010 B8 A4 and have bought the replacement OEM turbo and installation kit from ECS.

Some questions:
1) I realize this thread is for those upgrading to a K04 turbo, but I am assuming all the steps are the same as someone just replacing the turbo with an OEM one. Is there another thread or web link detailing the steps? This is the best one I have found so far.
2) Since I am not replacing the cat or down pipe, can I just undo the four turbo to cat bolts and replace the turbo? Is there enough room to get the turbo out? If not can I undo the four turbo to cat nuts and unhook the hangers to drop the exhaust?
3) Do I have to remove the O2 sensor from the cat?
4) From reading this, it seems to be a real PITA if the nuts come off the studs holding the manifold to the block. Any tips there to ensure the studs come out with the nuts? I am guess there is not enough room to get an impact wrench in there and heating the nuts would make the nuts more likely to thread off the studs. Soaking the studs and not the nuts with PB blaster?
5) is there a link to all the torque settings for the bolts during reassembly?

Thanks. Good suggestions for all the tools to get in order to make the job easier. My Amazon shopping cart is full!

Paul

[cuda2000]

Started the job of replacing my k03 today, got all the cat nuts off no problem, but now I'm stuck on the 6mm Allen heat shield bolt. I cant get a 6mm to fit into it like the original post said to. A 5.5mm fits all the way in but it's too loose. Every Allen wrench or bit I have hits the manifold. Thinking about cutting a 6mm L shaped allen down shorter, that's all I can think of at this point. Any other ideas?

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[cuda2000]

Started the job of replacing my k03 today, got all the cat nuts off no problem, but now I'm stuck on the 6mm Allen heat shield bolt. I cant get a 6mm to fit into it like the original post said to. A 5.5mm fits all the way in but it's too loose. Every Allen wrench or bit I have hits the manifold. Thinking about cutting a 6mm L shaped allen down shorter, that's all I can think of at this point. Any other ideas?

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I think I'm gonna drill it out....

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[PaulThBrit]

I just did this job and had a 6mm 3/8 drive socket that got it out with no problems. I am guessing the one I have is a little longer than yours.

Paul

[cuda2000]

I just did this job and had a 6mm 3/8 drive socket that got it out with no problems. I am guessing the one I have is a little longer than yours.

Paul

That's what I tried first. A 5 or 6 inch straight allen in a socket. I think that stripped it and it was downhill from there. If the metal is that soft I should be able to drill off the head in 10 minutes. I dont see a need for more than the 2 bolts on the sides. If she rattles, at least I have full boost with the rattle, gotta keep moving forward!

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[cuda2000]

That's what I tried first. A 5 or 6 inch straight allen in a socket. I think that stripped it and it was downhill from there. If the metal is that soft I should be able to drill off the head in 10 minutes. I dont see a need for more than the 2 bolts on the sides. If she rattles, at least I have full boost with the rattle, gotta keep moving forward!

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All right, after a call to suicide hotline and talked me out of jumping out 1st story window, I jammed a t40 torx bit into it and it turned out! Moving on to step #8!

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[cuda2000]

All right, after a call to suicide hotline and talked me out of jumping out 1st story window, I jammed a t40 torx bit into it and it turned out! Moving on to step #8!

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So I'm all ready to put the new turbo on. None of the studs came out when I removed it, but the turbo came right off just by removing the nuts only. Going back on and I cant seem to get it flush to the gasket. Do I need to remove the studs now, or loosen the bottom nuts on the 2 plates?20190527_152221.jpeg

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[cuda2000]

So I'm all ready to put the new turbo on. None of the studs came out when I removed it, but the turbo came right off just by removing the nuts only. Going back on and I cant seem to get it flush to the gasket. Do I need to remove the studs now, or loosen the bottom nuts on the 2 plates?20190527_152221.jpeg

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Ok never mind I loosened the plates and then tightened them up. And like magic, the turbo lines up just fine! Maybe loosening the plates dropped them down a bit, could be.

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[cuda2000]

Thanks to all for this thread and helping me vent my issues as I did the turbo swap.

I used this info to film a DIY K03 Turbo Replacement and ebay test pipe Video.

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/bW70AlIyof8

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[A4 Centaur]

Thanks!

[nataraki]

Subscribed for future use, thanks OP!

[Justin B8]

Subscribed for future use, thanks OP!

Tip to remove that bastard hex fitting on the heatshield before mangling it. Buy one of those 40 piece bit sets from Harbor Freight, the kind that comes in a red rubber block.
Use the 5mm hex bit and a long 1/4in wrench to remove it. A long bit hits the manifold; pretty much anything longer than 1/2in hits the manifold (bit, hex key, etc).

[Assetto31]

I have a question not directly about installing a KO4 but moreover a little clarification for a different project. I'm putting in an Oil Pressure gauge into the car and those of you who may have taken on this job with any TFSI engine may know the turbo oil feed line is the ideal spot to put in a banjo port for a pressure sender. I was just trying to figure out specifically which port is on the B8 KO3. Would it be the oil line circle in step 12 of this DIY?

If I'm not mistaken the circled port is the turbo feed and the turbo return line is on the other side and had a gasket connector rather than a banjo bolt.

If anyone could confirm that if they happen to know I'd be very appreciative.

Thanks, guys!

[unmarkedA4]

Correct


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[unmarkedA4]

I have a question not directly about installing a KO4 but moreover a little clarification for a different project. I'm putting in an Oil Pressure gauge into the car and those of you who may have taken on this job with any TFSI engine may know the turbo oil feed line is the ideal spot to put in a banjo port for a pressure sender. I was just trying to figure out specifically which port is on the B8 KO3. Would it be the oil line circle in step 12 of this DIY?

If I'm not mistaken the circled port is the turbo feed and the turbo return line is on the other side and had a gasket connector rather than a banjo bolt.

If anyone could confirm that if they happen to know I'd be very appreciative.

Thanks, guys!

Correct


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[KFizz]

So I'm way behind on this thread, but I'm finally installing a K04 on my Allroad. Everything went fairly well so far. New turbo is bolted in, but now I'm hung up on the passenger side coolant banjo. I cannot get the thing to thread in correctly. If I pull the banjo back, and try to thread the bolt straight into the turbo, it goes in pretty easy. When I try to thread it through the banjo fitting, I cannot get the treads lined up.

Is there any sort of trick to this? I've removed the M8 screw below which bolts the coolant line down. This gives me some extra play in the coolant line, but I still can't get it. This has been going on for hours, I'm at a loss. CTS K04.

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[unmarkedA4]

Everything lines up. Just take your time. The only thing i had attached to the turbo was the oil drain and the top coolant line.


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[KFizz]

Everything lines up. Just take your time. The only thing i had attached to the turbo was the oil drain and the top coolant line.


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I got it today. I finally got over my fear of cross threading it, and gave it a turn with the wrench. After that it went in smoothly. The thought of cross threading something this late into the job was unnerving.

[KFizz]

So that same coolant banjo was dripping a bit after startup. I was able to tighten it a little further. It seems to be seeping a little bit still. I've tightened it as much as I'm comfortable doing. I'm hoping it sort of seals itself after a couple heat cycles of the turbo.

Other than that it's looking pretty good. Had the outlet hose pop off on the first test drive. And it came off with some authority. Scared the shit out of me and some pedestrians in the area. It's tightened up better now.

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[unmarkedA4]

So that same coolant banjo was dripping a bit after startup. I was able to tighten it a little further. It seems to be seeping a little bit still. I've tightened it as much as I'm comfortable doing. I'm hoping it sort of seals itself after a couple heat cycles of the turbo.

Other than that it's looking pretty good. Had the outlet hose pop off on the first test drive. And it came off with some authority. Scared the shit out of me and some pedestrians in the area. It's tightened up better now.

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Did you use new crush seals? Should be using 2 Crush seals


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[KFizz]

Did you use new crush seals? Should be using 2 Crush seals


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Yeah I used 2 new washers, the inside one was a thicker spacer washer as well. I'm pretty positive that it's installed correctly, it's just not quite sealing.

[Audpor911]

My KO4 goes on Next week. Stock K03 is dying at 125K miles.

[Strikerusn]

Did anyone have any issues connecting intercooler house to turbo? I noticed my cts intercooler did not fit properly on my hpa k04 turbo? I noticed the intercooler house is bigger and the hpa doesn’t have a turbo muffler delete like the k03 does. Please help I don’t want to drive with a loose house :(

[Audpor911]

There is a 2.5" to 1.8" or so coupler conversion piece. This is what I have on my cat to adapt the 2.5" intercooler tube to the HPA K03.

[Audpor911]

https://www.ecstuning.com/b-ecs-part.../017623ecs08a/

[Stubek]

Going to do this later today.
Do I need any gasket adhesive for this?

[StuckAntichris]

I dont think you will. Just a new exhaust manifold gasket, new oil line gaskets & oil line O rings. and maybe some coolant line crush washers.

[Stubek]

Ok, started this today about noon my time and gave up around 445 as it was getting dark outside. I'm doing the CTS turbo. Overall, everything went fine, just a few hiccups of how the hell do I get a tool there.
Two minor adjustments to the DIY on the first page. The torx holding a bracket to the front of the engine right be the fan I was actually able to get a full length driver in there. I just had to slide it up into the fan housing rotate it, then into the screw so I could use it, that went pretty smooth.
Also, the exhaust heat shield that is supposed to be one 6mm allen and two M9 or M8 was actually three 6mm allens.

Got the new turbo in, just need to finish connecting up all the lines for it.

[Stubek]

ok, got it all together. Used option 2 for the first start up (run for a few seconds to pump oil and coolant then shut off and refill both). Restarted the car and it runs smooth, no code (P3 gauge), but lots of smoke. I don't see anything leaking, no puddles under the car or even drips. But lots of smoke. My guess is that when the coolant line came off the turbo and all that coolant came out, a lot went through the little "blanket" that wraps that line so its probably saturated and just needs to burn off.

[breierw]

Hey all, I know I am behind on this thread, but just looking for a second opinion...

Just got my new ko4 bolted up and all the fittings connected. Started it up for the first time and coolant gushed out of the lower coolant banjo on the turbo side. Leaking from both washers (between bolt and banjo, and between banjo and turbo).

I used the washers that came with the OEM hardware/gasket kit and seriously tightened the s**t out of them. I can't imagine the fitting is supposed to be tighter, so I am thinking either I overtightened the crush washers (unlikely) or the Chinese ko4 I bought doesn't have a flat mating surface for the banjo.

If anyone has experienced similar or has any advice please let me know! Looking forward to some fresh boost!!