Integrated Engineering VW MK6 GTI 2.0T TSI K04 Turbo Kit Install Thank you for purchasing another high quality Integrated Engineering product! This instruction guide is used for installation of IE’s K04 Turbocharger Upgrade Kit for VW MK6 2.0T TSI applications. This kit needs to be installed by a professional or an experienced technician. Integrated Engineering is not responsible for any damage caused by incorrect installation. Required Tools: Installation of this turbo kit will require a broad range of professional mechanic tools. You will be working with cramped spaces requiring multiple extensions, deep well sockets, flexible ratchets, torx screws, and triple square bolts. It is highly recommended you have access to a full professional quality tool chest to complete this job. Before You Begin: Open your IE K04 Turbo Kit, inspect all components, and verify their quantities. Allow the car to cool down completely and make sure you have adequate working room both on top and under the vehicle.

1. Park your car on a level surface, apply the parking brake, and prepare to lift the car safely off the ground. You will be required to perform a lot of work under the vehicle, for this reason it is highly recommended to use an auto lift for this procedure. Drain the coolant and oil from the vehicle.

2. Start the installation procedure by completely removing the air intake (stock or aftermarket).

3. Remove the coilpacks completely from the vehicle. It is recommended to replace all four coilpacks with new ones when upgrading to a K04.

4. Unplug the camshaft position sensor located on the side of the cylinder head.

5. Remove the three T30 and eight T25 bolts securing the belly pan to the bottom of the vehicle and remove the belly pan.

6. Remove the passenger side front wheel. Remove the seven T25 screws securing the lower fender liner to the vehicle, then remove the lower fender liner and set aside.

7. Unplug the two connectors from the diverter valve and N75 wastegate control valve.

8. Carefully place the coilpack wire harness off to the side of the engine bay out of the way.

9. Loosen the two T30 torx bolts and upper hose clamp on the plastic turbo outlet “J” pipe.

10. Pull to completely remove the spring clip located on the end of the plastic “J” pipe. With the clip removed, pull to release the intercooler inlet hose and completely remove the plastic “J” pipe.

11. Pull to remove the vacuum hose on the hardline located on top of the turbo heat shield.

12. Remove the two #8 triple square bolts from the hard line and heat shield. One is located on top of the heat shield, the second is located on the passenger back-side of the cylinder head.

13. Remove the 10mm nut from the hardline bracket located on the driver’s side of the cylinder head.

14. Locate the two soft lines connected to the heatshield hardlines on the passenger side of the vehicle. The first soft line is connected to the coolant reservoir. Using pliers, slide the hose clamp down the line off the barb and then remove the coolant overflow line from the coolant reservoir.

15. Remove the second evap softline located under the coolant reservoir by releasing the plastic push clip.

16. Disconnect the remaining coolant softline from the hardline. Use pliers to slide the hose clamp off the barb, and pull the coolant line off. The hardlines should now be free, pull them off the heat shield and place them out of the way next to the coilpack wire harness.

17. Disconnect the plastic push clip to release the evap check valve.

18. Using an 02 sensor socket and ratchet, remove the 02 sensor from the downpipe and place safely out of the way.

19. Remove the two 6mm allen bolts and two #10 triple square bolts from the rear of the turbo heat shield, then fully remove the heat shield from the vehicle.

20. Remove the four 16mm nuts from the downpipe to turbo flange. Pull the downpipe off the turbo compressor studs.

21. Remove the three #8 triple square bolts to release the turbo oil feed/return lines from the engine block.

Note: For easier access you may have to remove the CV axle heatshield, it is held on with two 16mm bolts.

22. Remove the #8 triple square bolt located under the diverter valve.

23. Remove the oil feed line #12 triple square banjo bolt from the top of the turbo. Completely remove the oil feed line and set aside.

24. Remove the #12 triple square banjo bolt from the turbo coolant return line.

25. Use pliers to slide the hose clamps off the barbs and remove the two coolant lines from the plastic hard lines located next to the oil filter.

26. Remove the two #10 triple square bolts that secure the turbo support bracket to the engine block.

27. Remove the 6mm hex bolt to remove the turbo support bracket from the turbocharger.

28. Remove the five 12mm copper nuts that secure the turbo manifold to the cylinder head. Then gently remove the entire turbocharger assembly from the vehicle.

29. Place the stock turbocharger on a clean surface next to your new K04 turbocharger. Before installing your new K04, you will have to transfer over a few accessories and lines. Begin by removing the three 5mm allen bolts from the diverter valve and carefully remove it from the stock turbocharger.

30. Line up the diverter valve locating stud onto the billet adapter plate pre-installed on your new K04 turbocharger.

31. Install the diverter valve using the new supplied 20mm 5mm allen head bolt and re-using two factory length 5mm allen head bolts. Install diverter valve bolts in the orientation pictured below:

32. Remove the two #8 triple square bolts from the oil return line and remove the entire line from the stock turbo.

33. Remove the oil return line gasket and clean the flange surface well. Install one of the new supplied gaskets and reinstall the line onto the K04 turbocharger in the same orientation as

stock.

34. Remove the #8 triple square banjo bolt from the turbo oil return line and reinstall onto your new K04 turbocharger in the same orientation using two supplied 14mm crush washers on both sides of the banjo.

35. Remove the one-time use clamp and remove the evap line from the stock turbo. Use the supplied new one time clamp and reinstall the evap line onto your new K04 turbocharger. Tighten the new clamp using an OE clamp tool or pair of wire cutters.

36. Apply some clean new oil to the oil feed opening on top of the new turbocharger.

37. Install the new supplied downpipe studs to the turbine housing using a stud install tool or “the double nut method”.

38. Your K04 turbo is now ready to be installed. Begin by placing the new supplied turbo manifold gasket in place on the rear of the cylinder head.

39. Carefully place the new K04 turbo assembly into the vehicle

40. Secure the turbo manifold to the cylinder head with the new supplied 12mm copper nuts. Torque all 5 nuts to 20 ft-lbs using a quality verified torque wrench.

41. Install the coolant return line onto the turbocharger using the new supplied crush washers. Make sure the larger copper crush washer sits on the bottom between the turbo and banjo line. Install the top supplied 14mm crush washer between the banjo bolt and banjo line and tighten the #12 triple square banjo bolt onto turbo.

42. Before reinstalling the turbo oil feed line, it will need to be modified. Mark a cut line on the edge of the bracket with a marker, make sure to mark it as close to the oil line as possible without going over the oil line itself.

43. Carefully follow your cut line using a cut-off wheel to completely remove the bracket from the oil feed line. Note: make sure to wear appropriate safety equipment and follow safety guidelines.

44. Clean the flange on the oil return line and reinstall to the block with a new supplied gasket.

45. Place the modified oil feed line back into the vehicle. Tighten all three #8 triple square bolts securing the oil feed and drain lines to the engine block.

46. Install the two supplied new 12mm crush washers onto the oil feed line and tighten the #12 triple square banjo bolt.

47. Install the new supplied turbo outlet silicone hose onto the turbo outlet adapter with supplied hose clamps.

48. Follow the install guide steps in reverse where applicable to reinstall all remaining factory parts. Fill the engine with fresh oil and coolant. Start the car and let idle to warm-up, inspect for any leaks. Verify coolant and oil levels, all hose clamps and connections are tight, and that all factory parts are fully installed before driving your vehicle. Enjoy the huge jump in performance

you will receive from your IE MK6 GTI K04 Turbo Kit!

Thank you for purchasing another Integrated Engineering product. We are dedicated to serving your VW/Audi engine and performance needs. Please check our website frequently for new product releases. If you have any questions or concerns about this product please do not hesitate to contact us. Integrated Engineering 801.484.2021 sales@performancebyie.com www.performancebyie.com