Description: Congratulations on your purchase of the AWE Tuning K04 Turbo Kit for your Mk5 2.0T.

Please note that a full turbo back performance exhaust is required for safe operation of this kit. We highly recommend 2.5” diameter exhaust systems for optimum power and boost pressure production. 3” diameter exhaust systems can negatively impact the turbo spool characteristics, resulting in slow boost production and also throttle and boost cut upon full boost production.

Installation of this turbo kit can be completed on jack stands or ramps. Never work under a vehicle only supported by a jack. If you do not feel comfortable installing this system yourself, contact a local professional for installation.

A.W.E. Tuning K04 turbo
A.W.E. Tuning turbo inlet coupler
A.W.E. Tuning noise pipe to diverter valve hose
A.W.E. Tuning diverter valve housing
A.W.E. compressor outlet hose
A.W.E. coolant feed line
Stock intake adapter coupler

Gaskets:

Manifold to head gasket
Turbo to down pipe gasket
Oil return line to turbo gasket
Oil return line to engine gasket
Oil feed line crush washer
Oil feed line to engine o-ring
Coolant line crush washer
Firewall gasket

Step 1:

Consult the factory manual for stock turbo removal. Removal of passenger side axle greatly eases removal and installation of the K04 turbo.

Make sure to remove the stock coolant feed line, shown at the arrow in Figure 1, as this will be replaced with an A.W.E. Tun- ing line.

Step 2:

Remove the pancake pipe shown at the arrow in Figure 2.

Copyright 2009, AWE Tuning. No part of this document may be reused or duplicated without the express permission of AWE Tuning/Secor Ltd. All rights reserved. Rev1.0

Step 3:

Install the coolant return line onto the K04 turbo using two of the included crush washers. Also use the supplied support bracket and Allen head bolt shown at the arrow in Figure 3.

Install the K04 turbo using the enclosed new gaskets and fas- teners. You may reattach the turbo end of the coolant return line at this time.

Do not install the other oil / coolant lines, turbo support bracket or intake for now.

Step 4:

Install the turbo outlet hose shown in Figure 4 using the in- cluded T-bolt clamps. The smaller clamp is used on the turbo side, the larger on the pancake pipe side. Re-install the OE pancake pipe at this time.

Step 5:

Install the included coolant return line. Attach the end with the 90 degree fitting to the engine block using the included hex head banjo bolt and two new crush washers. Orient the fitting as shown at the arrow in Figure 5. Leave the fittings loose for later adjustment.

Step 6:

Attach the 45 degree end to the turbo using the OE banjo bolt and two new crush washers. Leave the fittings loose until final adjustment

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