VW/Audi TSI Turbocharger Wastegate Repair
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- Опубликовано: 15 апр 2022
- All over the world thousands of these complete turbocharger assemblies have been replaced at cost of more than $1000 for the sake of a worn out bushing worth a few dollars! I fixed mine (NOT bent, shimmed, filed, sprung or added clip) and here I will show you how I did it.
Here is a link to the repair kit I used:
www.aliexpress.com/item/40005...
My CCZB engine uses the IHI RHF5 turbocharger.
I am not sure how similar the K03 turbo is. 
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Great video, anybody can replace parts with a new part but not everyone can repair them and this is what I enjoy doing repairing parts instead of wasting money on buying new parts, you learn so much more about the parts you’re repairing and is so much fulfilling. Good job 👍
Totally agree. Thank you.
Could probably run a business rebuilding these wastegates offering over half off from full turbo replacement.(have mechanic do this for 250 bucks or buy 1000 dollar turbo kit)
Very well done - thank you for putting this together for those motivated enough to do it
Great video, and very professional job. The best actuator repair I seen in yt.
Thank you very much.
Great craftsmanship. Motivated me to do the same. All worked great. Thanks a bunch.
I have been looking the video like this none of them showing as best as yours, absolutely great video I ever found, none of them showing professional ways how to repair the turbo,, well done Sir. Salute 🙏.
This is a very professional repair and after many more miles if the waste gate becomes loose again, you can just adjust it tighter like you did. Brilliant!
Thank you.
I did this job a while ago when i saw these kits came out. I didn't see the turbo smart part! I ended grinding off the pin on the end and having a machine shop make a new one and tack it back on.
I took out the bushing with a long bolt same way but with the impact. It came out without having to drill the roll pin. I didn't even know it had one. The pin fell out after in 2 parts.
very good job,professionally done
You absolutely nailed it with the instructions!
MATE! you won't believe how long i've been wondering what that noise was, well looks like a big xmas job for me. Thanks a lot for the detailed diy! will definitely follow that, very clear guide!
How'd it go?
That's a remarkably complete video, crushed it... Mine will likely come apart for a similar repair soon, have an intermittent P0299. Thanks for posting 👍
Thank you. Heaps more VW vids coming if you would like to subscribe and get notifications.
Great video! Inspired me to do it and it went easier for me to get that bushing out. You can use a punch or a bolt to hammer the bushing out instead of trying to extract it. Plenty of room in the housing.
I might need to replace later on as the housing is cracked at the wastgate opening unfortunately.
Great video.
I did exactly the same on a bmw m135i turbo
New subscriber just bc this video was informative enough that I watched the whole thing for no reason other than random knowledge
Welcome. Thank you for joining.
Nicely done. Way to be able to problem solve so well
That’s coolest video on wastegate rebuild!!!
Excellent, thank you so much. Just ordered parts to do mine. 🍻🇨🇦
Nice work Sir! Thank you for sharing 🙏
Great job. Good to see things being repaired rather than just replaced.
Absolutely. That pretty much sums up me! Thanks Pete.
Love the background music 🎵
Great job. Nicly executed.
Great video nice job thank you for sharing
Thank you so much ! Just neeed it ! And one more suggestion is best to use copper head to hit the bush into the housing instead of steel harmer
Yes a soft faced hammer would be perfect. Thanks for sharing.
Great video, thank you !
you are really a great master ..
Supersmart ! Thanks for sharing.
I always thought a turbo could not be saved. Good job!
It always depends on what the failure point is. Thank you.
Good point!@@PetesWorkshop
Wowwwwwwwwwww, éso es hacer mecánica.
Saludos desde México
Wow. Not an easy repair, good job
nicely done !!! well explained thxs for the parts info looked bit awkward but nothing that cant be done good repair without mega expense . result
briefly how you get the plugs leads off with damage to the coil packs if you can do vid on that be helpful thxs again Good Job !!!
God Bless You!
One year on… how’s it holding up? I noticed one of the comments on the repair kit said it was magnetic, yet the original is stainless. I’m wondering if that has any effect on the longevity?
Thanks for the great video - I agree it’s a complete waste to replace a whole turbo for a bush (or bushing, as us yanks call them!)
Better than original set
Perfect.
I got myself a clip that I put on mine, works like a charm. :)
This sounds good, but please explain further. What did you use the clip for? What kind of clip? Where did you put the clip? Thanks!
epc on my audi a3 comes on at cold start. i figured it was the acutator that got stuck or something but mor likely to be the wastegate right? hmm, i turn on the engine with a little gas, and no epc but i also rev it to 3000rpm everytime i start the engine.
Thats alot of work for just a waste gate flap. Great info though I have mk6 jetta 1.8t almost identical as that engine. And it seems it would be much more easy to replace turbo. Great job though!!!
Yep same engine just diff crank and pistons. Slightly diff turbo I think. Easier to replace, yes and also more than 10 times the cost.
@PetesWorkshop yes it is. But if I take the turbo off then I mine as well replace it due to only having 1 vehicle lol great job though
So everyone whos adding a clipper says that eventually the turbo will fail, would it still fail eventually with this process? Or it fixes the failure issue?
Herkese merhaba, Seat Leon FR 1.5EcoTSI 150ps act aracımda cold startta şıngırdama veya zırıl zırıl bir ses vardı sürekli kafamı kurcalıyordu ama bir türlü çözemiyordum bu videoyu izleyince sorunun kaynağını öğrendim ve gidip hemen kontrol ettim ve evet wastegate milinden geliyor ses ve elimle sabitlediğimde geçiyor. Bu bilgide ihtiyacı olan birilerine ilaç gibi gelecektir.
That's amazing. What is the bushing made of? Although your process is brilliant, have you considered drilling the old bushing out?
I think it is just steel. ‘Pulling’ the old bushing out is much easier than drilling it (in my opinion).
@@PetesWorkshop The pulling tool was brilliant, nice work
I just replaced my bushing today, hammering it through with a drift worked fine to get the old bushing out and was quick.
Hi Pete, thanks for the great video, I have a spare turbo that I will give a new waste gate flapper. I only have one question. Which diameter of drill did you use to drill the hole for the new roll pin? 3mm or a little less?
Kind regards ☺️
3mm drill bit is fine.
@@PetesWorkshop thanks a lot ☺️. So 3mm drill and a 3mm roll pin should do the trick.
Hi! First of all nice and useful video
Did you have problem creating a M6 thread in the 1/4 UNF?
Did you removed the previous thread with a drill or did you just forced the M6 male in the UNF thread?
I’ve actually just done this job again. No problem running an M6 tap straight through the 1/4 UNC internal thread. BUT the clearance of the shaft to internal was a bit large so I had to weld on an additional M6 nut to the Clevis so thread could be locked for adjustment.
Thanks for your reply! So if I understand well the welded nut is to ensure a better thread to the shaft. Could it be a good idea to weld the extra nut with an M6 screw inside to have the threads alligned?
@@mrwest77 yes you could rather weld on a M6 (or even better a 1/4 UNC) bolt to the shaft.
Pete, are the wear problems due to poor alloys? I don't think that the Mack trucks and JD tractors are prone to these failures.
Would you expect to do this repair again as a repair to the repair? Thanks, Dennis
Because I used the Turbosmart adjustable clevis, I doubt that I will ever need to replace the wastegate actuator. Perhaps just adjust it.
Thought my timing chain was going .. but no codes .. rattled on down revs .. turns out this is it .. (b8 a5 coupe 2.0 tfsi)
12:08 This is exactly how I thought I would repair a K03 turbo but how does one prevent the shaft from wearing on the bushing? It seems that the bushing is made from a material that is too hard for the shaft but should be made from a softer material such as a valve guide for example.
The clip is the only way to prevent it
@@Spindaoppblock So, by preventing wear in the actuator arm, the waste gate shaft wear is reduced?
I just got a new turbo in my Seat Leon 1,4 tsi 150 (pretty much a golf engine) but its as if the Wastegate arm still makes a little sound.
Is it true that its ok for the Wastegate to be a little loose when the engine is off, but has to be completly silent and locked when I turn on the engine? Because I noticed it still makes a little ratlle (once in a while), when I drive. Please help me😊
As long as your not loosing boost it probably doesn’t matter if it rattles occasionally. Just annoying! You could probably file the wastegate mounting holes then adjust to put a bit of pre-load on the push rod to stop the rattle. Also fitting that clip does help a lot too.
@@PetesWorkshop i've noticed that the rattle only comes when i push the brakes slightly and its down to 15- 10 mph. It does it three times. But Is that the same ? Or is it something else? Its not a sound from the brakes, Im pretty sure
@@TheWatersLundParty I’m really not sure. You could disconnect the pressure hose from the waste gate actuator (block off the open end) and drive it for a bit. Be careful though as your boost will spike high.
Doing this right now, how tight should the wastegate flapper be to the housing ?
Just touching plus a little bit more.
Hello is there an alternative for the turbo smart part I they don’t ship in Europe thx
I am not sure sorry. You may have to make the part.
The parts for the wastegate kit are out of order ! Are you aware of an equilivent kit?
You can find them on Amazon or Ebay that's where I purchased mine
Will a waste gate issues give a rich code as well P0172?
I’m not sure about that
Very novel work indeed...except that, for that process one would think to just purchase a new turbo as the cost of this repair and sourcing would cost more than a new turbo.
Bro how the fk am i going to find someone who will do what you just did!
My mk6 gti threw p0243 could this be the problem? It says wastegate solenoid A
P0243 indicates and electrical fault. I doubt this would be related to a worn wastegate actuator.
Any suggestions if I can't weld?
If you prep it and set it up it is a 2min job for someone that can weld. It could even be done with a stick welder.
My car has the same issue I believe is this not supposed to be driven just got the check engine light a few days ago replaced DV and that wasn’t it believe it is this issue
Hey mate. Unlikely to cause engine damage if you keep driving. Just annoying rattle and lower engine power.
will my mechanic do this if i buy the part
Highly unlikely! Most mechanics are only interested in swapping parts rather than repairing mechanical failures. You can sure ask though as some mechanics will do this kind of repair.
How much did this improve the car??
I rarely had low boost issues but the rattle really annoyed me because I knew exactly what the problem was. So much better when that rattle is gone.
I feel bad for all the people who got sold a new turbo when this was all that it needed.
Blame the mechanics for not fixing it and the Audi dealer makes ALOT of money
wish I had the tools
9:47 next time put a bolt in the bushing to protect it from hammering...
Not hammering, ‘Just tap in. Tap tap taparoo’ hehe
@@PetesWorkshop ya, great job! keep doing it that way! To put a bolt in as protection would have too many disadvantages anyway...
Great video, better if he didn't blast music.
Agreed. Let me try to fix that.
Epc light??
Very rarely I would get a check engine light with low boost warning
@@PetesWorkshopthank you😊
How much would this job cost? Think mechanics would even do it?
I think very few mechanics would consider doing this work. I guess it would take approximately 4-6 hrs, to remove the turbo, do the work, replace the turbo with new seals and gaskets. Its not going to be cheap. Unless you do it yourself. Good luck.
do you trust aliexpress is it safe
Great I'm out of luck 🙁
Why are you out of luck?
How about a normal fix