I married to a Chinese national. We both live outside the USA. She does not have a SS# or ITIN#. I want to file my tax returns on TurboTax. I completed W7 application

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for her to obtain the ITIN#. How should I proceed in filing my tax returns? Should I mail in both return and W7 and send by courier to IRS?

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Yes you would need to send in both your W-7 with your attached tax return to the IRS.

Here are some additional steps for filing married filing jointly if spouse needs an ITIN. 

• leave NRA spouse's SSN blank and print a paper copy of your tax return.
• skip error check section if only error is missing SSN for spouse.
• under the file tab, you will need to select "file by mail" and print a copy of your federal income tax return.
• attach a statement, signed by both spouses, to your joint return for the first tax year for which the choice applies (Nonresident Spouse Treated as a Resident). It should contain the following information:
•  A declaration that one spouse was a non-resident alien and the other spouse a U.S. citizen or resident alien on the last day of your tax year, and that you choose to be treated as U.S. residents for the entire tax year.
• The name, address, and identification number of each spouse.
• apply for NRA spouse’s Individual Taxpayer Identification Number (ITIN) using Form W-7 (Click ITIN).
• attach a copy of your Form W-7 (along with the necessary supporting documents) to your tax return (For the supporting documents, one option is for your NRA spouse to get a certified copy of his/her passport which will need to be included with your tax return filing.) Click here for IRS website  ITIN - Frequently Asked Questions .
• mail your tax return along with your declaration statement, Form W-7 and supporting documents to the IRS. According to the IRS, because you are filing your tax return as an attachment to your (ITIN) application, you should not mail your return to the address listed in the Form 1040, 1040A or 1040EZ instructions. Instead, send your return, Form W-7 and proof of identity and foreign status documents to:
  
       Internal Revenue Service
       Austin Service Center
       ITIN Operation
       P.O. Box 149342
       Austin, TX 78714-9342 
  
  You may also apply for an ITIN using the services of an IRS-authorized Acceptance Agent or visit some key IRS Taxpayer Assistance Center in lieu of mailing your information to the IRS in Austin.