I have. 2004 tt 225 BEA and had an exhaust leak and had someone replace the bolt and gasket between the exhaust manifold and turbo and one (1 of 3) of the bolts fell out again.
When taking the bolts out this time after finally getting them out I found out that the bolts thread into a threaded (threaded insert) that threads into the receiving end of the top of the turbo bracket. Well of course it wasn't the bolt that came out.. It backed the threaded insert out. In order to get the bushing off the bolt (2 of 3),, I had to use some vicegrip pliers in doing so it destroyed the threaded insert. The last bolt (3 of 3) also backed out the threaded insert but I was able to use some ingenuity to get the bushing off the bolt without destroying it. I took pictures of the bolt and bushing
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https://www.audizine.com/forum/images/attach/jpg.gif
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I called Audi parts and they had no part that identified the threaded insert being attached to the turbo.
Searching online I found an image of the Borgwarner K 04 which shows the insert on the turbo bracket that mates up with the exhaust manifold.
https://www.audizine.com/forum/images/attach/jpg.gif
1). I need to get another bushing and am looking at BW website. Anyone run into this before? Know where to get one?
2). Is the Borgwarner K04 the stock turbo? Or is it aftermarket? If it didn't show up on the Audi parts list, makes me think it wasn't the stock turbo (I bought the car used)
3) Has anyone pulled their turbo without pulling the engine? Any advice on the approach for the task (before I start tearing more things apart)? Advice on getting the turbo to down pipe header?
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