DIY: Audi Turbo Flapper Replacement Install (Common Problem)

[vladtech]

I bought a used 2010 Audi A4 not too long ago and it was purchased with a boost problem

While doing a thorough inspection I noticed the flapper arm had too much play inside of the bushing.
So I went ahead and ordered a new flapper kit online to fix the turbo myself.

I figured I'd use the extra money from not having to buy a brand new turbo and put it towards basic maintenance parts to possibly add some go-fast bits later on.

If interested, you can click HERE for the link where I bought the flapper kit.

Tools Required:

• Grinder
• Welder
• Drill

1. Remove e-clip from the metal wastegate arm.

2. Remove the wastegate actuator and inspect the pin for wear. If the pin shows wear, replace the actuator.

3. Grind off the weld spot on the metal wastegate arm.


4. Take pliers and remove the arm by bending it back and forth.

5. Drill out the stopper pin for the bushing by using a ⅛ drill bit.

6. Push bushing inside of the manifold. You can do this by hammering it in with a 10mm socket.


7. Once the flapper is removed, make sure to inspect the area where the flapper arm sits on the manifold for cracks. If you see a crack, replace the manifold!

8. Clean the hole for the new bushing.

9. Install the new bushing using a soft piece of metal to not damage anything. Stop at 10mm from the manifold surface and constantly check how the flapper is seated.



10. Once the bushing is installed with its proper height of 10mm, take a ⅛ drill bit and drill a slot for the lock pin. Make sure to use a HIGH rpm! The drill bit can break if not done correctly!

11. After drilling the lock pin hole, install the new lock pin.

12. Weld the new flapper arm in a half-moon position and make sure they have the same angle. Press together the arm and flapper firmly but not too tight! If the flapper and arm are welded together tightly, it WILL jam on operation!

13. Install old e-clip.

14. Use a pressure hand pump to verify wastegate functionality.

[rcprato]

You are definitely the right person to own a 2019 A4 !! I bought a rebuilt turbo for my 09 A4 Avant because of the same problem and the rebuilt turbo came with this exact same waste gate repair/modification as what you just shared and envious of people on here that can take on these problems and fix themselves.

So easy to get caught up in the appeal of this car when looking for a nice used car but they can nickle/dime you to death with these annoying repairs that a lot of people buying their first Audi could never imagine.
Again, AWESOME JOB !

[vladtech]

Thank you for the kind words! It's true that these foreign cars can eat your wallet out but doing a job like this isn't that difficult. It's much easier to do this kind of work when you have a DIY guide like the one I provided.

[Artyaa]

Hello, what’s the result? Did you gain HP /boost?
Thanks