K03 out!
12-31-2006, 03:09 AM
#21
AudiWorld Expert
Thread Starter
I left the oil line on the oil pan...
I removed the turbo's lower support, which gave better access to the 2 bolts holding the oil line to the turbo. Then removed the oil line from the turbo.
12-31-2006, 06:58 AM
#23
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That's crazy clean! Say, I'll be doing a similar install shortly...
Same turbo, along with the Milltek HFC. Do you have any tips for the removing the KO3? Also, can you provide some more input on how you managed the liquids. And finally, what tools (over and above the obvious) make this install easier?
12-31-2006, 10:17 AM
#26
AudiWorld Expert
Thread Starter
IAW the Factory Repair manual....
Coolant supply line to turbocharger 35Nm
Coolant line bracket to turbocharger 10Nm
Turbocharger to exhaust manifold 35Nm 1)2)
1) Replace bolts
2) Coat thread and contact surface of bolt head with hot bolt paste G 052 112 A3
Turbocharger bracket to cylinder block 25Nm
Turbocharger bracket to turbocharger 30Nm
Catalytic converter to turbocharger 30Nm
Oil return line to turbocharger 10Nm
Oil supply line to turbocharger 23Nm
Oil supply line bracket to cylinder head 23Nm
Heat shield to secondary air line 3.5Nm
Hose clamps for coolant hoses 2Nm
Hose clamps for air hoses 3.5Nm
Coolant line bracket to turbocharger 10Nm
Turbocharger to exhaust manifold 35Nm 1)2)
1) Replace bolts
2) Coat thread and contact surface of bolt head with hot bolt paste G 052 112 A3
Turbocharger bracket to cylinder block 25Nm
Turbocharger bracket to turbocharger 30Nm
Catalytic converter to turbocharger 30Nm
Oil return line to turbocharger 10Nm
Oil supply line to turbocharger 23Nm
Oil supply line bracket to cylinder head 23Nm
Heat shield to secondary air line 3.5Nm
Hose clamps for coolant hoses 2Nm
Hose clamps for air hoses 3.5Nm
01-01-2007, 04:06 PM
#30
AudiWorld Expert
Thread Starter
These....
<center><img src="https://erwin.volkswagen.de/workshop/englisch/pictures/3094.jpg"></center><p>
Hose clamps limit the coolant from draining considerably. ;O)
Removing the turbo, I removed the diverter valve with hoses attached, intake pipe from intercooler-2-turbo, the boost resevior. Basically everything under the turbo. Then removed the lower turbo brace(2-bolt) which allows better access to the lower oil line. Which does not have to be removed from the oil pan. Remove lower oil line from turbo.
*Note- lower oil line gasket of metalic. Dont let parts retailer try to sell you a "paper" gasket. It wont hold pressure. Get the metal one. ;O) Cover inlet of lower oil line to keep dirt out. I used aluminum foil.
Remove the air-box.
Remove secondary air-line.
Remove heat-shield.
Install hose-clamps on upper coolant line and lower coolant line.
Remove upper coolant line from turbo, Residual coolant will come out.
**Lower coolant line will be removed once turbo is un-bolted. Dont unbolt lower coolant line from engine block! Otherwise coolant will drain consideraly!**
Remove the entire intake tube(gensing root) leaving as many of the hoses attached.
"Note- get replacement hose clamps for these ahead of time for re-install"
Once the turbo intake hose is removed, it gives you room to move the turbo forward, off the exhaust/cat/test-pipe. Plus aids re-install.
Remove the 3 turbo-2-cat nuts.
Loosen the 3 turbo-2-manifold bolts. **May require spray lube to aid removal**
Hold onto the turbo while removing manifold bolts
Once the turbo is unbolted you can turn the turbo towards you, about 1/2 turn. and place one of the exhaust studs back into the cat. This is to gain access to the coolant line bolt, to remove it. Its a metric-allen head bolt. Once removed, the turbo can be pulled out.
Hose clamps limit the coolant from draining considerably. ;O)
Removing the turbo, I removed the diverter valve with hoses attached, intake pipe from intercooler-2-turbo, the boost resevior. Basically everything under the turbo. Then removed the lower turbo brace(2-bolt) which allows better access to the lower oil line. Which does not have to be removed from the oil pan. Remove lower oil line from turbo.
*Note- lower oil line gasket of metalic. Dont let parts retailer try to sell you a "paper" gasket. It wont hold pressure. Get the metal one. ;O) Cover inlet of lower oil line to keep dirt out. I used aluminum foil.
Remove the air-box.
Remove secondary air-line.
Remove heat-shield.
Install hose-clamps on upper coolant line and lower coolant line.
Remove upper coolant line from turbo, Residual coolant will come out.
**Lower coolant line will be removed once turbo is un-bolted. Dont unbolt lower coolant line from engine block! Otherwise coolant will drain consideraly!**
Remove the entire intake tube(gensing root) leaving as many of the hoses attached.
"Note- get replacement hose clamps for these ahead of time for re-install"
Once the turbo intake hose is removed, it gives you room to move the turbo forward, off the exhaust/cat/test-pipe. Plus aids re-install.
Remove the 3 turbo-2-cat nuts.
Loosen the 3 turbo-2-manifold bolts. **May require spray lube to aid removal**
Hold onto the turbo while removing manifold bolts
Once the turbo is unbolted you can turn the turbo towards you, about 1/2 turn. and place one of the exhaust studs back into the cat. This is to gain access to the coolant line bolt, to remove it. Its a metric-allen head bolt. Once removed, the turbo can be pulled out.