Ko3 turbo - IDI Engine - VWDiesel.net The IDI, TDI, and mTDI source.

• Ko3 turbo by ffgb on 05 Jul, 2012 20:44
• I am thinking of adding a ko3 turbo on my 1984 1.6N/A.  I have a couple of questions of installation.  How is the boost controlled on the turbo?  I see there is an actuator on the turbo, is that how the turbo boost is controlled?  If so, how do you control the actuator?  If it is vacuum controlled, what part of the motor do you attach the vacuum hose too?
  
  I see at times used diesel ko3 turbo's and manifolds for sale and I am thinking of going in that direction for a turbo setup.  I see that the manifold has an egr outlet, do you weld those shut???  Can I use an 1980's CIS gasser intake manifold, will it clear with that turbo and exhaust manifold setup???
  
  Any and all information about installation and problems would be grateful before I start collecting/buying the diesel ko3 turbo, exhaust manifold, etc...
• #1 by Blocksmith on 06 Jul, 2012 08:51
• Quote from: ffgb on 05 Jul, 2012 20:44

  I am thinking of adding a ko3 turbo on my 1984 1.6N/A. Good choice for a nice torque gain!
  I have a couple of questions of installation.  How is the boost controlled on the turbo?  I see there is an actuator on the turbo, is that how the turbo boost is controlled?  Yes, that actuator controls the wastegate, which allows the exhaust to bypass the turbine wheel once the exhaust manifold pressure reaches a certain point in order to limit boost and keep the turbo from overspooling and killing itself.
  If so, how do you control the actuator?  If it is vacuum controlled, what part of the motor do you attach the vacuum hose too? The wastegate actuator is controlled by boost, and should be connected to your intake manifold. You will need to block off the hole in the compressor housing that it will leave, though. You can use a manual boost controller (such as this--  http://www.ebay.com/itm/NXS-MANUAL-BOOST-CONTROLLER-100-ROCK-STEADY-NO-SPIKING-/260344245934?pt=Motors_Car_Truck_Parts_Accessories&hash=item3c9db9eeae&vxp=mtr ) to trick the actuator into opening later and making the turbo give you more boost.
  
  I see at times used diesel ko3 turbo's and manifolds for sale and I am thinking of going in that direction for a turbo setup.
  I see that the manifold has an egr outlet, do you weld those shut??? I would. Some people try to put EGT probes in them, but they're usually not in the direct flow of the exhaust where you want it to be. If you want to put an EGT probe in, just drill and tap a hole right in front of the turbo.
  Can I use an 1980's CIS gasser intake manifold, will it clear with that turbo and exhaust manifold setup??? I'm not entirely sure about a TDI k03 (which might be oriented like a VNT, which is out then down, not up), but an AAZ k03, which is oriented like a 1.6 turbo, absolutely will not work with a gasser manifold unless you flip the turbo and its manifold upside down, which is problematic in its own right. You have to reclock the turbo to get the oil draining the right way, and then there's the issue of the exhaust outlet being on the wrong side; it would making fabbing a downpipe sooooo much harder. There's a reason the turbo manifolds are the shape that they are--there's just no room for anything else.
  
  Any and all information about installation and problems would be grateful before I start collecting/buying the diesel ko3 turbo, exhaust manifold, etc...
  
• #2 by CrazyAndy on 06 Jul, 2012 16:04
• Will you be adding a TD pump, or will this be running 'Eco-style'?
• #3 by ffgb on 07 Jul, 2012 14:28
• Thanks for the replies!
  I will be running my stock N/A pump.  I just want extra pep, especially down low, and be able to maintain speed on hills.
• #4 by Blocksmith on 07 Jul, 2012 16:48
• I would think a k03 would be the perfect turbo for what you've described. Make sure the wastegate works properly, though. As for the NA pump, don't forget to do the gov mod (searching the forums will bring up more info than you will care to read...), and maybe adjust the max fuel screw a little as well. With those two modifications you should be able to see at least 75-80hp, with power coming on waaaaaaay sooner than if you had a stock T3 / k24 turbo setup. How much boost are you planning on running? From what I understand, k03's are happy up until around 15psi. Will you be installing boost and EGT gauges?
• #5 by ffgb on 07 Jul, 2012 18:43
• How would know for sure if the wastegate is working? Especially if I buy the turbo without seeing it in person?  If they saw the wastegate is stiff and doesnt move freely, is it bad?  If it is bad, can u replace the wastegate?
• #6 by RabbitJockey on 08 Jul, 2012 03:12
• A lot of the ko3 turbos get a some what seized waste gate but they cAn usually be worked free