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  1. #1
    Established Member Two Rings
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    Audi TT Quattro MK1 1.8T, Audi A4 Quattro B6 1.8T, 10th AE Mazda MX5 1.8I, 1986 Honda XL250R
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    KY Louisville

    Snapped turbo bolt...

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    Okay so the manifold where it attaches to the turbo i kept backing out the bolts, so I got it EXTRA tight today which resulted in snapping one of the 3 bolts attaching the turbo to the manifold on top there. My question is what are the immediate issues with running it like this and also what should i do to extract it, bolt extractor and drill but will that work on a super tight bolt?

  2. #2
    Senior Member Three Rings
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    Nov 10 2015
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    Sudbury, ON

    drill it, and easy out. should come out. heat manifold
    2004 Audi A4Q 1.8T Ultrasport 6MT
    Frankenturbo'd, Meth, front mount, custom tune, full exhaust, bunch of other crap
    2004 Audi A4 Quattro 1.8T Tip Sport Pkg SOLD
    18" S4 Avus wheels l Eibach Lowering springs l Magnaflow 16601 l 3" TP l Pioneer Double Din l USP Bumper/S4 Door blades/Spoiler l Black on Black

  3. #3
    Established Member Two Rings
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    KY Louisville

    And if I keep it running with the 2 bolts for a bit what can I expect?

  4. #4
    Senior Member Three Rings
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    Quote Originally Posted by nsh95 View Post
    And if I keep it running with the 2 bolts for a bit what can I expect?
    exhaust leak, other snapped bolts, cracks
    2004 Audi A4Q 1.8T Ultrasport 6MT
    Frankenturbo'd, Meth, front mount, custom tune, full exhaust, bunch of other crap
    2004 Audi A4 Quattro 1.8T Tip Sport Pkg SOLD
    18" S4 Avus wheels l Eibach Lowering springs l Magnaflow 16601 l 3" TP l Pioneer Double Din l USP Bumper/S4 Door blades/Spoiler l Black on Black

  5. #5
    Senior Member Two Rings
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    Oct 07 2008
    AZ Member #
    33928
    My Garage
    05’ GLI 1.8T_4motion, 07’ A4 3.2_quattro
    Location
    Calgary, AB.

    Running with that leak will roast your turbo to mani gasket and also throw your fuel trims off. I suspect boost onset might be kind of jerky too.

    If enough of the bolt is exposed you might be able to clamp on to it and back it out but if it’s uber tight, like you said, then you might end up having to drill it out and tap new threads... I’ve used helicoil with success... timesert is another one.

  6. #6
    Established Member Two Rings
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    KY Louisville

    So here is what I am working with..
    http://pasteboard.co/pCM0e3uRK.jpg
    http://pasteboard.co/2yStEAnRZ.jpg
    http://pasteboard.co/pCNArUkga.jpg
    I can't get directly to the bolt with a drill because those lines are in the way, should I remove the turbo or try to move the lines out of the way?

  7. #7
    Established Member Two Rings 123lilc's Avatar
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    Mar 04 2015
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    2002 Audi A4 GTX3071R, 2004 Audi S4 Avant 6M/T, 2008 Audi A4 Cabriolet,2018 L5P Duramax
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    Champaign, Illinois

    if you have small enough hands just remove the manifold from the head and then take out the other 2 turbo bolts then drill it out that way. removing the airbox assembly will make this easyer, but if you do this you will have to buy new exhaust manifold nuts becouse they are one time use. also if you choose this route then you might as well get a new manifold gasket and new turbo gasket

  8. #8
    Established Member Two Rings
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    Quote Originally Posted by 123lilc View Post
    if you have small enough hands just remove the manifold from the head and then take out the other 2 turbo bolts then drill it out that way. removing the airbox assembly will make this easyer, but if you do this you will have to buy new exhaust manifold nuts becouse they are one time use. also if you choose this route then you might as well get a new manifold gasket and new turbo gasket
    Yeah but those lines in the third photo hover right above the hole where i need the drill to be so I can do anything with that in the way.. I no longer have the factory air box and deleted the secondary intake also.

  9. #9
    Established Member Two Rings 123lilc's Avatar
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    2002 Audi A4 GTX3071R, 2004 Audi S4 Avant 6M/T, 2008 Audi A4 Cabriolet,2018 L5P Duramax
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    Quote Originally Posted by nsh95 View Post
    Yeah but those lines in the third photo hover right above the hole where i need the drill to be so I can do anything with that in the way.. I no longer have the factory air box and deleted the secondary intake also.
    you can remove the heat sheild
    i believe the black one is PCV (dont quote me on that im not for sure, yours looks a little different than mine) and the silver one is oil supply line. you should be able to remove the PCV line. for the oil supply line, it is bolted on the side of the head and the back of the head you should be able to remove the bolts and slightly move the line out of the way.
    Last edited by 123lilc; 11-10-2016 at 12:59 PM.

  10. #10
    Veteran Member Four Rings jjvwg's Avatar
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    why would you remove the manifold? that sounds like a pain in the dick. do yourself a favor and pull the turbo. with it out of car you'll have the freedom to do whatever you have to do to get the snapped bolt out.
    | 2004 A4 Avant | Gloss Dark Grey |
    | 2.7t K04 swap | 034 RSB | Apikol snub | 17z BBK |Vogtland GT1 Coilovers | Moog adj. UCA's | Peeler reps |

    | 2011 A4 Avant | Brilliant Black | 6MT swap | APR S2 | APR Downpipe | Vogtland Coilovers | RSE's | 034 Sway/tranny mount | Q5 brakes |

  11. #11
    Established Member Two Rings 123lilc's Avatar
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    Quote Originally Posted by jjvwg View Post
    why would you remove the manifold? that sounds like a pain in the dick. do yourself a favor and pull the turbo. with it out of car you'll have the freedom to do whatever you have to do to get the snapped bolt out.
    i feel like it would be more apain to remove the turbo because then you have to drain coolant and oil
    just my opinion

  12. #12
    Established Member Two Rings
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    KY Louisville

    I agree, fiddled with it for a few hours and just can't get enough work space in there to get a straight shot at it with the drill even with the lines out of the way. Be pulling it soon as I get a chance I guess. >.< Appreciate it folks!

  13. #13
    Veteran Member Four Rings jjvwg's Avatar
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    Quote Originally Posted by 123lilc View Post
    i feel like it would be more apain to remove the turbo because then you have to drain coolant and oil
    just my opinion
    draining the oil and coolant takes all of 5-10 minutes. never pulled the exhaust manifold but people make it sound like its the absolute worst thing you can do on these cars. People bitch about taking it off with the motor out of the car. plus, you can pinch off the coolant lines and not even worry about that, so its basically just like doing an oil change to pull the turbo quick for something like this.
    | 2004 A4 Avant | Gloss Dark Grey |
    | 2.7t K04 swap | 034 RSB | Apikol snub | 17z BBK |Vogtland GT1 Coilovers | Moog adj. UCA's | Peeler reps |

    | 2011 A4 Avant | Brilliant Black | 6MT swap | APR S2 | APR Downpipe | Vogtland Coilovers | RSE's | 034 Sway/tranny mount | Q5 brakes |

  14. #14
    Senior Member Three Rings crazyquik22023's Avatar
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    Quote Originally Posted by jjvwg View Post
    draining the oil and coolant takes all of 5-10 minutes. never pulled the exhaust manifold but people make it sound like its the absolute worst thing you can do on these cars. People bitch about taking it off with the motor out of the car. plus, you can pinch off the coolant lines and not even worry about that, so its basically just like doing an oil change to pull the turbo quick for something like this.
    I disagree, removing the manifold is the best option and is much easier than removing the turbo. Loosen the other 2 17mm turbo to manifold bolts, then remove the 10 13mm nuts from the manifold to the cylinder head. IMO much easier than removing the turbo. If you are lucky there might be enough of the broken bolt off that you can grab onto it with a pair of locking vice grips and get it out. If not the bolt is large enough that you should be able to easily drill into it and use an EZ out. Just remember to put a rag or something into the turbo to avoid getting metal shavings in the turbo. And I'm not sure which line you are referring to "pinching" off, but you are definitely not pinching off the feed or return water lines that connect to the turbo.

  15. #15
    Veteran Member Four Rings jjvwg's Avatar
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    Quote Originally Posted by crazyquik22023 View Post
    And I'm not sure which line you are referring to "pinching" off, but you are definitely not pinching off the feed or return water lines that connect to the turbo.
    why not? ive done it a few times. up to the guy doing the work i guess but pulling the turbo is quick and painless IMO. especially if he says the stock airbox isnt there. hell, if there is enough of the bolt sticking out, he could probably even just undo the last two bolts to the manifold, undo the cat bolts and push the turbo over enough to get some vice grips on it and twist it out. might have to undo the oil feed line to get some more movement but you dont have to drain the oil to pull that one off.
    | 2004 A4 Avant | Gloss Dark Grey |
    | 2.7t K04 swap | 034 RSB | Apikol snub | 17z BBK |Vogtland GT1 Coilovers | Moog adj. UCA's | Peeler reps |

    | 2011 A4 Avant | Brilliant Black | 6MT swap | APR S2 | APR Downpipe | Vogtland Coilovers | RSE's | 034 Sway/tranny mount | Q5 brakes |

  16. #16
    Established Member Two Rings
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    Quote Originally Posted by jjvwg View Post
    why not? ive done it a few times. up to the guy doing the work i guess but pulling the turbo is quick and painless IMO. especially if he says the stock airbox isnt there. hell, if there is enough of the bolt sticking out, he could probably even just undo the last two bolts to the manifold, undo the cat bolts and push the turbo over enough to get some vice grips on it and twist it out. might have to undo the oil feed line to get some more movement but you dont have to drain the oil to pull that one off.
    This is essentially what I hope I can get away with pulling from the top tweaking out and removing the bolt.. WE shall see how it goes. Thanks everyone really appreciate this community!

  17. #17
    Veteran Member Four Rings eljay's Avatar
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    nsh95, have you extracted your snapped bolt yet?
    I believe mine just snapped - the same location as yours. I put a stick in the hole of the missing bolt and measured 58mm from the mounting plate down and that happens to be the same or very close to the thickness of the mounting plane of the manifold. I have a high-flow manifold (034, I believe), so I'm sure I need a different size bolts. As a side note, does anyone know the bolt size/length for the 03 high-flow manifold?
    So, yeah, I think mines i snapped right at the turbo since I couldn't insert my stick further down than then thickness of the manifold mount. :(
    I think I will attempt to get at it by removing the manifold and see if I can extract the bolt somehow with the turbo in the car.
    Current: 2016 Audi A4 Allroad (in progress)
    Past: 2005 Audi A4 1.8T Quattro Avant / 6-speed / Ultrasport - SOLD

  18. #18
    Veteran Member Four Rings fR3ZNO's Avatar
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    Necro bump, but anybody have any suggestions on how to remove that bolt. Just snapped the same one on my B5 as I was removing the turbo. There’s no stick out so no easy way to grab it with vice grips. I was thinking drilling and attempting to use an easy out along with some heat...
    "If one does not fail at times, then one has not challenged himself." - Ferdinand Porsche

  19. #19
    Veteran Member Four Rings b6Hate4's Avatar
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    Quote Originally Posted by fR3ZNO View Post
    Necro bump, but anybody have any suggestions on how to remove that bolt. Just snapped the same one on my B5 as I was removing the turbo. There’s no stick out so no easy way to grab it with vice grips. I was thinking drilling and attempting to use an easy out along with some heat...
    Thats going to be tough without an oxy acetylene torch. Can give it a try or just remove turbine housing off the turbo and swap it out with a good one.
    2016 S3

    2004 S4- 2.7t, Shaved bay, wire tucked, PTE5858 single turbo full build.

    Instagram- @Thisisastickup

  20. #20
    Veteran Member Four Rings eljay's Avatar
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    Quote Originally Posted by fR3ZNO View Post
    Necro bump, but anybody have any suggestions on how to remove that bolt. Just snapped the same one on my B5 as I was removing the turbo. There’s no stick out so no easy way to grab it with vice grips. I was thinking drilling and attempting to use an easy out along with some heat...
    I removed the turbo and took it to a shop and they drilled it out, I believe.
    Current: 2016 Audi A4 Allroad (in progress)
    Past: 2005 Audi A4 1.8T Quattro Avant / 6-speed / Ultrasport - SOLD

  21. #21
    Veteran Member Four Rings fR3ZNO's Avatar
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    Quote Originally Posted by b6Hate4 View Post
    Thats going to be tough without an oxy acetylene torch. Can give it a try or just remove turbine housing off the turbo and swap it out with a good one.
    Thankfully I have an oxy acetylene torch. lol. I don’t have a good housing to swap with. I would imagine the bolts are fairly hard like a grade 12.9 or something so I’m sure drilling it will be fun...
    "If one does not fail at times, then one has not challenged himself." - Ferdinand Porsche

  22. #22
    Veteran Member Four Rings fR3ZNO's Avatar
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    Quote Originally Posted by eljay View Post
    I removed the turbo and took it to a shop and they drilled it out, I believe.
    Gotcha. That doesn’t sound too bad, I do have some m10 helicoil if all else fails lol
    "If one does not fail at times, then one has not challenged himself." - Ferdinand Porsche

  23. #23
    Veteran Member Four Rings eljay's Avatar
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    Quote Originally Posted by fR3ZNO View Post
    Gotcha. That doesn’t sound too bad, I do have some m10 helicoil if all else fails lol
    Yeah, I'm not sure how they did it, but it came back to me with all threads intact. They spent 1.5 hours on it, but charged me less. So, it must've been painful.
    Current: 2016 Audi A4 Allroad (in progress)
    Past: 2005 Audi A4 1.8T Quattro Avant / 6-speed / Ultrasport - SOLD

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