Author Topic: k24 - service/swap options  (Read 4987 times)

Reply #15July 19, 2017, 12:13:39 pm

oblique

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Re: k24 - service/swap options
« Reply #15 on: July 19, 2017, 12:13:39 pm »
Thanks for the input, much appreciated.

Reply #16July 20, 2017, 03:31:16 pm

fatmobile

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Re: k24 - service/swap options
« Reply #16 on: July 20, 2017, 03:31:16 pm »
No gasket between exhaust manifold and turbo,... right?
 Just some silicone.
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with a re-ringed, '84 quantum, turbo diesel, MD block

Reply #17July 20, 2017, 04:17:20 pm

RabbitJockey

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Re: k24 - service/swap options
« Reply #17 on: July 20, 2017, 04:17:20 pm »
there is no gasket and usually no sealer, but i think i will try some hylomar or some exhaust puddy when i reinstall my turbo tonight.
01 Jetta TDI 100% stock daily
81 Rabbit:TDI-M ported head, Frank06 cam, PD intake, hybrid T3 turbo, Renault intercooler, Syl20 11mm pump, light weight fw, and yellow California Clutch clutch kit

Reply #18August 01, 2017, 04:11:01 pm

oblique

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Re: k24 - service/swap options
« Reply #18 on: August 01, 2017, 04:11:01 pm »
Turbo swap was a bit of a bear but it went well. Only took a day and a half including all new gaskets behind the motor. The four 12 point bolts holding turbo to manifold took 2 of us to loosen cleanly but after that it was ok. I urge anyone doing this to take the time clean all hardware and threads with tap and die as they mine were quite bad. The hardware that holds the downpipe to the bracket coming from the manifold was the worst.

The T3 has an awesome sound. Its like a low pitched whiney whistle in 2nd gear...love it.

So with a new pump, injectors, air filter, and good turbo my car still smokes quite significantly at WOT after the turbo spools. I'm assuming after all this work that this is normal?

Edit: Also, what should I do with the old K24? Shaft play is actually really quite good minimal. Had no oil consumption when I had it in.
« Last Edit: August 01, 2017, 04:14:47 pm by oblique »

Reply #19August 01, 2017, 09:02:11 pm

vanbcguy

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Re: k24 - service/swap options
« Reply #19 on: August 01, 2017, 09:02:11 pm »
Smoke can be adjusted using the LDA and max fuel screw on the pump. Or you can turn up the boost... ;-)

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1994 Jetta - AHU M-TDI - Jezebel Jetta
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Reply #20August 02, 2017, 08:12:18 am

RabbitJockey

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Re: k24 - service/swap options
« Reply #20 on: August 02, 2017, 08:12:18 am »
keep the k24 as a spare?
01 Jetta TDI 100% stock daily
81 Rabbit:TDI-M ported head, Frank06 cam, PD intake, hybrid T3 turbo, Renault intercooler, Syl20 11mm pump, light weight fw, and yellow California Clutch clutch kit

Reply #21August 04, 2017, 12:05:04 am

oblique

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Re: k24 - service/swap options
« Reply #21 on: August 04, 2017, 12:05:04 am »
True enough. There's a k24 rebuild thread that I bumped recently which had the photobucket ransom thing happening...is there any update on that? Is everyone just moving hosts? A lot of excellent threads have been lost. Our reliance on digital data has a price it seems.

Reply #22August 04, 2017, 07:34:14 am

RabbitJockey

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Re: k24 - service/swap options
« Reply #22 on: August 04, 2017, 07:34:14 am »
its very unfortunate.  i think the description and checking other websites for how to rebuild a turbo would give you enough info on how to do it. Turbos are all put together nearly the same and they're pretty simple too.
01 Jetta TDI 100% stock daily
81 Rabbit:TDI-M ported head, Frank06 cam, PD intake, hybrid T3 turbo, Renault intercooler, Syl20 11mm pump, light weight fw, and yellow California Clutch clutch kit

Reply #23August 08, 2017, 04:45:39 pm

oblique

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Re: k24 - service/swap options
« Reply #23 on: August 08, 2017, 04:45:39 pm »
I'm going to attempt servicing the wastegate. One thing the missing photos from jake's thread would help with is the slide hammering the seals part. The cover of the wastegate seems to be pressed and folded over the body and I assume after I get it off I'll know what to do?

Reply #24August 09, 2017, 07:18:48 am

RabbitJockey

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Re: k24 - service/swap options
« Reply #24 on: August 09, 2017, 07:18:48 am »
are you trying to service the t3 wastegate?  that can't be done don't mess with it you can only break it... just test it if anything.
01 Jetta TDI 100% stock daily
81 Rabbit:TDI-M ported head, Frank06 cam, PD intake, hybrid T3 turbo, Renault intercooler, Syl20 11mm pump, light weight fw, and yellow California Clutch clutch kit

Reply #25August 14, 2017, 12:24:04 pm

oblique

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Re: k24 - service/swap options
« Reply #25 on: August 14, 2017, 12:24:04 pm »
Sorry I meant the k24 wastegate while I have the turbo off.

Jake's k24 thread with broken pics:

http://vwdiesel.net/forum/index.php/topic,13357.0.html

Reply #26August 21, 2017, 11:33:35 pm

oblique

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Re: k24 - service/swap options
« Reply #26 on: August 21, 2017, 11:33:35 pm »

Got around to removing the wastegate from the k24. Few questions. The valve did not appear to be stuck - that is, maybe the removal process loosened it but it slides freely without any noticeable grit or skips in its travel - however - its very stiff. makes 30 lbs of hand pressure or more to close it - is this normal?

The banjo fitting that came off the wastegate had soot inside - is this a leak?

I see theres a 10mm allen slot at the bottom of the valve but it doesnt loosen anything when I turn it - whats the next step in disassembly process?

The turbines looked fine but the locknut looks like its missing an edge?

Snapped the head off one of the wastegate securing bolts - is it a standard drill out and extract on these?







Reply #27August 22, 2017, 12:37:03 am

vanbcguy

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Re: k24 - service/swap options
« Reply #27 on: August 22, 2017, 12:37:03 am »
Wastegate doesn't come apart any more than that. About 30 lbs of hand pressure sounds about right, there's probably about 3 square inches of diaphragm in the actuator so that'd be 10 PSI boost pressure. That center Allen bolt thing can make small changes to the preload on the return spring - nothing significant, like within 1.5 PSI of the design set point. It's also a vent that'll let some boost pressure out for cooling purposes so don't worry if the actuator doesn't hold pressure.

Normal to see the missing bit on the compressor and / or turbine nuts. That's from high speed balancing of the assembled turbo. They grind a little off the nuts as required to balance the assembly.

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Bryn

1994 Jetta - AHU M-TDI - Jezebel Jetta
2004 Jetta Wagon - 1.8T - Blitzen

Reply #28August 22, 2017, 07:57:45 am

RabbitJockey

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Re: k24 - service/swap options
« Reply #28 on: August 22, 2017, 07:57:45 am »
i always thought that 3mm allen adjusted how far the valve could open
01 Jetta TDI 100% stock daily
81 Rabbit:TDI-M ported head, Frank06 cam, PD intake, hybrid T3 turbo, Renault intercooler, Syl20 11mm pump, light weight fw, and yellow California Clutch clutch kit

Reply #29August 23, 2017, 12:36:57 pm

oblique

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Re: k24 - service/swap options
« Reply #29 on: August 23, 2017, 12:36:57 pm »
Thanks for replies and good info.

So assuming the wastegate was stuck ( I think the hammering action loosened it) and its not serviceable - whats the best way to clean it? Do I just work in some anti seize along the valve stem and hope for the best? 

Its amazing that it got stuck in the 'open' position though...all that spring pressure still didnt allow it to close. So what causes this? A long, high RPM highway drive where the wastegate remained open for a long time?

Is the T3 wastegate superior becuase it has the 2 hoses to the wastegate which both push and pull on the valve?

 

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