CTS K04 oil and coolant line issues.

[Nano909]

Did anyone using a CTS K04 have issues with the oil and coolant lines from the B8 not fit onto the turbo?
This is in regards to a CTS K04 I bought last year when they were still welding an extension onto the turbo.

Thanks in advance

[bb-tt]

Just the coolant line think Iceman (maybe someone else) had same issue had to swap to the top coolant port and put plug in lower port. Then had to stack two copper washers under the coolant banjo bolt/flange or whatever you call that connector the banjo bolt goes through so the line would clear the plug otherwise it leaked like a seive.

Did you modify the lines as shown in the installation instructions?

[Nano909]

Did you modify the lines as shown in the installation instructions?

By modify you mean cut the bracket?

[bb-tt]

Yes, even with the bracket cut could not get coolant line to line up with lower port

[Nano909]

Yes, even with the bracket cut could not get coolant line to line up with lower port

Hmmm, and here I was wondering if I got sent the wrong turbo. Lol

[bb-tt]

Hmmm, and here I was wondering if I got sent the wrong turbo. Lol

To be more specific it lined up but could not get the banjo bolt to start without it feeling like it was cross threading.

[Nano909]

To be more specific it lined up but could not get the banjo bolt to start without it feeling like it was cross threading.

Do you know what post this info was on?

[bb-tt]

One of the k04 threads probably around sep 2018

[Nano909]

One of the k04 threads probably around sep 2018

Damn, well I'll start searching. Thanks a lot!

[bb-tt]

Mar 8 2019 in the k04 owners follow up thread . It was a response to you.

Quote Originally Posted by Nano909 View Post
My CTS K04 came in today. Not too sure I want to install the HFC I got with it now since my smog guy says I won't need it. But I'm super excited.


So I found half of my notes, the most important thing is going to be having the t55 torx for the cooling lines an Allen wrench fits also can't remember what size, if you could find a t55 Apex bit that would be Ideal. You are going to need a Dremel or something to cut the brackets off the cooling lines. If you have a gfb diverter you will need one longer bolt can't remember the size to bolt on to the adapter that keeps the dv in the stock location. Also in mine I could not get the cooling line to line up with the lower port (kept wanting to crossthread) so I moved the plug from the top port to the lower port. Then the coolant leaked as the cooling line went directly over the sealing plug for the lower port and kept it from correctly seating. I solved by using two crush washers under the cooling line supposedly the kit comes with 1 thicker crush washer, I did not notice and was not taking everything back apart to find so for less than a dollar bought a couple stock crush washers at the Audi dealer. Everything else was pretty straight forward, you can download the install directions although when I did they had not updated them for keeping the dv in stock location. If I remember anything else I will let you know. Oh if you have the eurocode turbo muffler delete with the larger outlet you will need to get a stock size hose from there to the intercooler inlet. Speaking of which I need to post a bunch of parts in the classifieds.

[Iceman502]

Just the coolant line think Iceman (maybe someone else) had same issue had to swap to the top coolant port and put plug in lower port. Then had to stack two copper washers under the coolant banjo bolt/flange or whatever you call that connector the banjo bolt goes through so the line would clear the plug otherwise it leaked like a seive.

Did you modify the lines as shown in the installation instructions?

Yeah, when I installed mine (see ebay K04 thread), I had to stack two crush washers on top of each other for the coolant feed line. The core had two ports on two of the sides creating some seating issues since the plugs protruded. And I will say that it was a pain to thread in as well. Getting it started was very challenging due to tension on the line, and once it was, it certainly felt like I was cross-threading. Since I had failed to get it started so many times, I kept going and it proved to be watertight.

That was the only line I had to double stack washers. Unfortunately, I forgot the outside crush washer on the banjo bolt for the coolant return line under the exhaust manifold, but it seated well enough that I haven't had an issue. Also, ensure the oil return line gasket is seating correctly on the bottom of the turbo. Mine was not which lead to a leak, and getting to that to replace it with the turbo installed is one of the worst things I've had to do on this car.

[spin0rz]

I had many issues with mine.

Overly tight coolant and oil return line. Coolant line drips here and there. Oil line went full pissing mode at one point. Had to change the oring.

I did have to relocate the coolant line. Also what a pain in the ass to bolt the banjo bolt.. Better off putting that damn thing on before sliding turbo in.


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[Nano909]

Mar 8 2019 in the k04 owners follow up thread . It was a response to you.

Wooooooow, I'm such an idiot. I knew I remembered something about it. Good thing I posted here.

[Nano909]

Yeah, when I installed mine (see ebay K04 thread), I had to stack two crush washers on top of each other for the coolant feed line. The core had two ports on two of the sides creating some seating issues since the plugs protruded. And I will say that it was a pain to thread in as well. Getting it started was very challenging due to tension on the line, and once it was, it certainly felt like I was cross-threading. Since I had failed to get it started so many times, I kept going and it proved to be watertight.

That was the only line I had to double stack washers. Unfortunately, I forgot the outside crush washer on the banjo bolt for the coolant return line under the exhaust manifold, but it seated well enough that I haven't had an issue. Also, ensure the oil return line gasket is seating correctly on the bottom of the turbo. Mine was not which lead to a leak, and getting to that to replace it with the turbo installed is one of the worst things I've had to do on this car.

Thanks for responding. I have the car in a very reputable shop, so I'll pass the info along and see if they can do it.

- - - Updated - - -

I had many issues with mine.

Overly tight coolant and oil return line. Coolant line drips here and there. Oil line went full pissing mode at one point. Had to change the oring.

I did have to relocate the coolant line. Also what a pain in the ass to bolt the banjo bolt.. Better off putting that damn thing on before sliding turbo in.


Sent from my iPhone using Audizine

Wish I screenshot that post at the time. Smh

[Der Konig]

I mean it was a little tight getting everything to fit but in the end got it all sorted. No issues here. Put it on only 500 miles or so ago. Just had to be patient and make sure everything was lined up correctly.

Oh, no double stack washers or anything. Just modified brackets like they said.

[Perry01]

I mean it was a little tight getting everything to fit but in the end got it all sorted. No issues here.... Just had to be patient and make sure everything was lined up correctly.

Oh, no double stack washers or anything. Just modified brackets like they said.

Same here, no issues with the installation.

[Nano909]

Thanks for the replies everyone. Turbo is on the car. We had to make a new oil line since the old one was pretty beat from the oil leak it had. Made a steel braided oil line and also got the cam cover resealed.

[Nano909]

Same here, no issues with the installation.

Hey the IE K04 file is based on yours right?

[Perry01]

Hey the IE K04 file is based on yours right?

Along with a manual trans. B8 A4 that the owner purchased in SLC for dyno testing.

[Nano909]

Along with a manual trans. B8 A4 that the owner purchased in SLC for dyno testing.

I'm making the switch to IE for the K04. Hopefully it doesn't disappoint.

[Perry01]

I'm making the switch to IE for the K04. Hopefully it doesn't disappoint.

After downloading the file, drive it a hundred miles, log some data and send the logs to [email protected] , Ask them to take a look. If adjustments are needed, they will fine tune it.

[Nano909]

After downloading the file, drive it a hundred miles, log some data and send the logs to [email protected] , Ask them to take a look. If adjustments are needed, they will fine tune it.

Cool. What's the break in period like for the CTS?

[Der Konig]

Most turbo manufacturers recommend an hour of operation before full load from what I've seen.

Cool. What's the break in period like for the CTS?

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[Iceman502]

Cool. What's the break in period like for the CTS?

Pull the fuse on the fuel pump the first time you start it so that the coolant and oil have an opportunity to pump through the core. Overwhelmingly, that was the most important piece of info I read repeatedly through various forums and technical sites outlining turbo installations.

Following that, I'd go by Der Konig's suggestion and just drive it normally for maybe 50 or so miles to ensure everything is airtight and lubricated properly.

[Nano909]

Pull the fuse on the fuel pump the first time you start it so that the coolant and oil have an opportunity to pump through the core. Overwhelmingly, that was the most important piece of info I read repeatedly through various forums and technical sites outlining turbo installations.

Following that, I'd go by Der Konig's suggestion and just drive it normally for maybe 50 or so miles to ensure everything is airtight and lubricated properly.

Nice, can't wait to let it rip!

[Der Konig]

Good call, definitely do this. Some say unnecessary but its such a simple and easy precaution.

After my engine build I did 4 bursts of about 12 to 15 seconds to prime the whole engine. So I would go for around that to ensure lubrication.

Pull the fuse on the fuel pump the first time you start it so that the coolant and oil have an opportunity to pump through the core. Overwhelmingly, that was the most important piece of info I read repeatedly through various forums and technical sites outlining turbo installations.

Following that, I'd go by Der Konig's suggestion and just drive it normally for maybe 50 or so miles to ensure everything is airtight and lubricated properly.

Sent from my SM-G965U using Audizine mobile app

[audilife23]

I just swapped my stock IHI K03 turbo to a CTS K04. Got all the lines swapped over and got the turbo installed. I'm having a coolant leak, not from the lines but from the port plugs on both sides. It is a very slow leak but still a concern. Has anyone else had this issue or recommendations on a fix?