DIY K04 Install Notes/Helpful Tips

[RichBGTI]

So brute force prevailed. Removed what bolts I could from the heatshield and then fatigued the shield until it broke off. I'll deal with the bolt once the turbo is off and can access more freely and replace heatshield. Tried a torx and bigger hex hammered in to no success.

Got a screw extraction kit coming tomorrow so will give that a pop.

Got the 5 manifold bolts loosened and with the heat shield out the way. Can see and with relative ease get to the downpipe studs with a socket, so things are looking up!


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[lilfleck]

So the heatshield bolt is connected to the manifold not the head?

[RichBGTI]

No, it's in the head.


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[Geryon86]

Originally Posted by lilfleck

So the heatshield bolt is connected to the manifold not the head?

[Brunkel]

Sub'd! Great write up!


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[RichBGTI]

These writeups really are invaluable!


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[RichBGTI]

So that plug.

Different position on TSI. It's between cylinder 3 and 4 around the same height as the pic above.

Once the the turbo was off, I was able to get the plug out. I could see what it may have been taken out at some point in the past and was already a bit rounded off which prevent the hex from fully seating. Was able to hammer in a hex and was fine. Hard to check when everything is in the way.

hammering in an XZN bit does the job too!


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[Geryon86]

Originally Posted by RichBGTI

So that plug.

Different position on TSI. It's between cylinder 3 and 4 around the same height as the pic above.

That is a TSI and it is between cylinder 3 & 4. It's a picture of the back of the engine with a mirror.

[RichBGTI]

Originally Posted by Geryon86

That is a TSI and it is between cylinder 3 & 4. It's a picture of the back of the engine with a mirror.

Ha, didn't spot the mirror!


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[Brunkel]

Are these just basic locking plyers? The eBay link you posted is down.

[XGC75]

^^ for those and the bolt holding the banjo on the fluid line to the turbo it's best to use a triple square set with some kind of hex pattern on the bit just before the socket end. What I did was to put the M(something) into the bolt, then used a 10mm crescent wrench to torque the M(something) bit.

Edit: like so:



Sincerely, XGC75

[Brunkel]

Originally Posted by XGC75

^^ for those and the bolt holding the banjo on the fluid line to the turbo it's best to use a triple square set with some kind of hex pattern on the bit just before the socket end. What I did was to put the M(something) into the bolt, then used a 10mm crescent wrench to torque the M(something) bit.

Edit: like so:



Sincerely, XGC75

Nice! I have the this kit per this thread: https://www.amazon.com/gp/product/B0...?ie=UTF8&psc=1

so that should definitely work. What other tricks you got for this install!?
Ordered my long reach ball head hex socket set for the 6mm...
Just from reading everything I feel like when the heat shield comes off it should just rain beer from all cylinders in celebration.

EDIT. Holy crap...I see you're in SW Michigan. Where at? I'm 20 minutes from the boarder.

[Mk6 Steve]

Originally Posted by lilfleck

lilfleck's K04 Install Notes/Tips


Additional Recommended Hardware:
Exhaust Manifold Studs (there are 5, but you don't need to replace them unless they break) - N0444115
6mm Allen Screws on Turbo Support (1x) - (not sure of PN)
6mm* (skinny) Allen Screws on Turbo Heat Shield (2x) - M8 X 1.25 (not sure of PN)
6mm* (fat) Allen Screw on Turbo Heat Shield (1x) - (not sure of PN)

Sorry to bring this thread back from the dead but I wanted to add a little info to the thread about some part numbers that will make the parts list a little more complete. Maybe the OP will add it to the original thread so future users don't suffer set backs like myself and like plenty of others in the past have as well I'm sure...

In regards to tools I don't have anything special to add other than to reiterate as stated before and make sure you follow this thread word for word. Without long ball hex sockets/allen wrenches as well as this tool kit (https://www.amazon.com/gp/product/B0...=1):happyanim:) that has a combination of long and short hex, torx and triple square this job wouldn't be pleasant by any stretch! Also instead of PBlaster I was recommended that I use this other stuff called AeroKroil. Its a little pricey but it works far better and I've been using PBlaster for 2 decades! But anyways lets get to the good stuff...

Exhaust manifold studs (attaches exhaust manifold to block) - M8 X 44 - N0145555

(1)Turbo support bracket (upper 6 mm hex bolt) - N91103701

Heat shield (has 2 different bolts, but 3 bolts need to be removed in total):
(1) 6 mm hex plug - N0160255
(2) 6 mm hex bolt - N01627801

(1)Oetiker clamp 15.7 mm - N10199201