SOmeone may have to correct me, but the local turbo guy told me that that thing is actually threaded in. The three bolts aren't actually holding it together.

Thanks Andy2!

Another question along these lines: Do you know if the wastegate can be disassembled or opened up somehow?  Or is the end cap permanently swaged on? (It looks like it might be...)  Would removing the nut and possibly the allen-headed stud sticking out of the end help it come apart somehow?  Is that just connected internally to an adjustable spring seat?  Thanks again.

Here is a pic of this turbo:

When I took a customers turbo for inspection the TurboDude could get mine apart, he went and got it redicularsley hot, it came apart then.
He tried levers and hammers with no avail after the screws were removed.
As it happened the actuator was completely jammed, hence problem with car.
Actuator was on back order (For and AAZ) for a good few months, he managed to find a recon unit and fitted that instead.

Pics!

Here is where I started today:


The wastegate was stuck...


So following Andy2's advice, I slide hammered those heat shields out of there!  Here is what it looked like when they came out... lots of carbon built up:


The wastegate passages are kind of interesting.  The gasses flow in toward the wastegate.  Could the wastegate really get a good seal on this valve seat???

Some wastegate measurements:
wastegate valve seat ID: 24mm
wastegate valve head diameter: 31mm
wastegate installed travel/pre-load: 2mm

pressure to reach 2mm travel: 10 psi (approximate.  Note: it is very "sticky" when completely closed.)
max travel: 10mm (8mm travel from touching the valve seat)
pressure to reach max travel: approx 14 psi
These wastegate pressure measurements pretty closely match what is published in the SAE paper:


Some detail of the turbine wheel.  The vanes look pretty aerodynamic.  I am impressed overall with the quality of this KKK turbo...

Turbine wheel specs:
OD: 59mm
exducer bore diameter: 49.5mm
thickness of fin section: 21mm

Compressor section "GW" before disassembly:


Here is what the inside of the compressor housing looks like:

Diffuser style is like most modern turbos, a parallel wall diffuser.  The outer wall looks like a separate piece of metal that is pressed into the main housing.

Compressor wheel is a backward curved impeller type.  This allows for more efficiency although less pressure ratio capability.  Detailed shot:

The measurements of the compressor wheel are:
inducer bore: 37.5mm
OD: 60.5mm

And here is what the cartridge looks like (AKA the "guts" of the turbo...)  A large colored o-ring seals the compressor housing to the cartridge.


I also tried to get some measurements necessary to calculate the turbine housing A/R ratio...

This thickness of 8mm was measured at a 59mm diameter.

I found a local turbo parts distributor/rebuild shop that has a rebuild kit for this turbo.  Is $100 a decent price for a turbo rebuild kit?

Have you tried turbo_city?

http://www.turbocity.com/default.php?cPath=15_20

No affiliation...  Not sure which kit would work for you, but I see that the 300-300 kit lists some VW's...

I'm working on taking one of these apart and this thread has been very helpful.
 I called one guy and he said to mic the parts to make sure I get the right size bearings and stuff.
 He said a generic kit doesn't always fit right. Not a one-size-fits-all kinda deal.
 Majestic turbo or something like that.