1) is it a K03?
Yes.
2) are there different types of K03 such as 'sport'?
Yes. K03 refers to the frame/bearing housing size. The next digits in the part number are the configuration. There are probably hundreds of different wheel trims and compressor and turbine housings for this frame size. The K03 sport you mentioned is a 1.8T gas hotside with a K04 compressor wheel. It is meant for the 1.8T, it is not suitable for a diesel.
3) what are the direct bolt-on turbo options for this engine?
Depends on your definition of "bolt on". There are no other turbo's that will bolt on to your exhaust manifold and fit your downpipe but there is another manifold that bolts to your head and can take a wide variety of turbo's. You will have to fab up your own downpipe for most turbo swaps. The 4 bolt 1.6TD manifold will accept a garret T2, a T3 from a 1.6TD (not all T3's), K14, K24 and possibly a K26 though I'm not sure if the K26 compressor could be made to clear the intake manifold.
4) I plan on getting my pump rebuilt or doing it myself. I am installing a FMIC that is approx 18"x5"x2". I can get my turbo rebuilt or get any turbo i want for a good price so Q4 is... suggestions for turbo solution?
Alot of people use the K24 from the 1.6TD on 1.9TD's with good results. I still run the stock K03. I like the instant boost but I'm sure its holding back the top end power. I think the K14 would be the best compromise but they are very rare...
5) i left injectors and downpipe out because I don't know much about them. if these are things that I should really consider investing in then please let me know.
If the stock injectors have more than 200000km on them i would suggest new nozzles. I'm using nozzles from the european 80hp RA/SB engine in the stock 2 spring injector bodies with good results. They can be purchased from "Smog" in the "for sale" section. It wouldn't hurt to have a 2.5" downpipe but there isn't a lot of room back there. You're going to have to build it yourself there aren't any aftermarket downpipes available.
6) anyone heard of fabricating a converter so i could bolt a tdi/whatever is better(not bigger, better) turbo to my idi exhaust manifold? would this be worthwhile?
No need for an adaptor, the TDI manifold will bolt right on. The later variable nozzle TDI turbo's have a manifold that is cast as an integral part of the turbine housing, so you pretty much have to use it... The TDI turbo's all use vacuum operated wastegates (or vacuum operated variable vanes in the 99.5 and up and NB engines). The VNT turbo might be of some advantage but you would have to come up with a control system and actuator that operated from manifold pressure rather than vacuum. The VNT has also proven to be a bit fragile, there have been a number of failures, how many of those were due to abuse is difficult to say though... The earlier wastegate turbo's are very close to the same units as used on the 1.9TD. They are quite reliable, but I don't see any advantage there.
Topic: turbo setup (Read 2485 times)
