Table of Contents
The Golf R is a high-performance vehicle that can be further enhanced with a turbo upgrade. This guide provides a step-by-step process for installing the BorgWarner KP39 turbocharger, a popular choice among enthusiasts looking to boost their vehicle’s power and efficiency.
Tools and Materials Needed
- Torque wrench
- Socket set
- Wrenches
- Screwdrivers
- Gasket scraper
- New turbocharger: BorgWarner KP39
- New gaskets and seals
- Oil and coolant
- Safety glasses and gloves
Preparation Steps
Before starting the installation, ensure that you have all the necessary tools and materials ready. It’s crucial to work in a well-ventilated area and wear appropriate safety gear throughout the process.
1. Disconnect the Battery
Begin by disconnecting the negative terminal of the battery to prevent any electrical shorts during the installation process.
2. Remove Engine Cover
Next, remove the engine cover by unscrewing the bolts that secure it in place. This will give you better access to the turbocharger and surrounding components.
Removing the Old Turbocharger
With the engine cover removed, you can now focus on taking out the old turbocharger. Follow these steps carefully to ensure a clean removal.
1. Detach the Exhaust Manifold
Loosen and remove the bolts connecting the exhaust manifold to the turbocharger. Be cautious as some exhaust components may be hot.
2. Disconnect Oil and Coolant Lines
Carefully disconnect the oil and coolant lines from the turbocharger. Make sure to have a container ready to catch any leaking fluids.
3. Remove the Turbocharger
Once the oil and coolant lines are disconnected, remove the bolts securing the turbocharger to the engine. Carefully lift the turbocharger out of its housing.
Installing the BorgWarner KP39 Turbocharger
Now that the old turbocharger is removed, it’s time to install the new BorgWarner KP39 turbocharger. Follow these steps for a successful installation.
1. Prepare the New Turbocharger
Before installation, inspect the new turbocharger for any damage. Ensure that all the necessary gaskets and seals are in place.
2. Install the Turbocharger
Position the new turbocharger in place and secure it using the bolts previously removed. Tighten the bolts to the manufacturer’s specifications using a torque wrench.
3. Reconnect Oil and Coolant Lines
Reconnect the oil and coolant lines to the new turbocharger, ensuring that they are tight and leak-free.
4. Reattach the Exhaust Manifold
Reattach the exhaust manifold to the turbocharger and secure it with the bolts. Double-check that everything is snug and properly aligned.
Final Steps
After installing the new turbocharger, it’s essential to complete a few final steps to ensure everything is functioning correctly.
1. Reinstall the Engine Cover
Replace the engine cover and secure it with the bolts removed earlier. This will protect the engine components and give your engine bay a clean look.
2. Reconnect the Battery
Reconnect the negative terminal of the battery. Make sure it is secure to prevent any electrical issues.
3. Start the Engine
Start the engine and allow it to idle for a few minutes. Check for any leaks around the turbocharger and ensure that all components are functioning correctly.
4. Test Drive
Finally, take the vehicle for a test drive to ensure that the new turbocharger is performing as expected. Monitor the boost levels and engine performance.
Conclusion
Upgrading to a BorgWarner KP39 turbocharger can significantly enhance the performance of your Golf R. By following this step-by-step guide, you can ensure a successful installation and enjoy the benefits of improved power and efficiency.