996 TT turbocharger replacement

[ebaker]

From the shop manual. I have not done this (yet). You should probably use tubing wrenches on the oil lines.

1)remove rear bumper cover

2)remove center heat shield and intercooler assembly and side heat shield(s)

3)undo upper oil pipe at the uppermost connection while counterholding the larger connection below with an "open ring wrench" (tubing wrench)

4)remove upper turbo support nut/bolt

5)pull vac line

6)undo 2 oil pipes on oil container

7)pull pressure pipe from turbo (hose clamp)

8)undo 4 turbo flange to cat nuts

9)undo header from head

10)remove turbo with header

Install (use new seals/metal gaskets)

1)fit turbo to header

2install header to head, torque in an inner to outer pattern to 18 ft lbs then to 25 ft lbs

3)tighten 4 flange to cat nuts

4)tighten 2 oil tank lines 22 ft lb

5)attach upper turbo support then attach upper oil line 15 ft lb

6)install side heat shields

7)install pressure pipe with hose clamp

8)install intercooler 17 ft lb

9)tighten sheetmetal nuts on side heat shields

10)install intercooler hoses , "snap" into place

11)carry out "oil level and tightness test"

It might be a good idea to crank the car with the fuel pump relay pulled to oil the turbos before you start the engine.