Turbo issues... repair or upgrade?

[addautomotive]

So, the k03 on my 96 aaz jetta has been getting noisier and noisier. I bought a bearing kit from Jake Russel, and finally got the time to pull my turbo apart yesterday. Unfortunately, the exhaust side's compressor wheel is toast. Looks like it literally melted away at the tips of the vanes.

Picture:


So here are my options:
-Replace this compressor wheel with a decent one, use the bearing kit that I bought. Anyone have one??

-Replace my turbo altogether... anyone have one?

-Replace the k03 with a k24. What kind of rigging would this take? It looks like the downpipes are different. I just bought a brand new downpipe a few months ago... it would kill me to pitch it.
I know some of you have mounted k24s on 1.9s How did you do it?

[Dr. Diesel]

I put a K24 on chris-pl's AAZ passat.

http://vwdiesel.net/phpBB/viewtopic.php?t=398&highlight=k24

[addautomotive]

hmm... the k24 I looked at yesterday had a different downpile than mine. Mine is almost rectangular.

[HP]

Is that from an Audi? VW's K24's usually have trapezoidal form flange, I think!

[andy2]

I've modified the AAZ/k03 downpipe to fit k24,k14,t2,t3.All you need to do is leave the top two holes alone they line up.The bottom part of the flange needs to be cut off and two more holes will need to be drilled thats all.Basically just get any of the turbos mentioned above and you'll see what I mean.

For a bigger turbo install you will need the 4 bolt manifold that's used with any of the bigger ones.

For the 1.6 turbos(k24,t3) you would need the bigger intake hose.Also there is the oil drain pipe that you would have to modified.

Both the k14 and t2 already used on the 1.9 are considerably bigger than the ko3 already and will be a direct bolt on with the only the manifold needing to be changed.Both of these turbos are good for 20 psi and a considerable amount of fuel while still giving great spool up,unlike the t3,k24.The t3,k24 will work but are not worth installing if your not looking for over 100hp 25+psi boost.

In the end It may just depend on which turbo is the easiest to come by

[addautomotive]

HP, I wasn't very clear in that last post. The picture is the downpipe currently on my car... for it's k03 turbo.

Andy, thanks for all the tips... that's the info  I've been looking for.

I've modified the AAZ/k03 downpipe to fit k24,k14,t2,t3.All you need to do is leave the top two holes alone they line up.The bottom part of the flange needs to be cut off and two more holes will need to be drilled thats all.Basically just get any of the turbos mentioned above and you'll see what I mean.

Other than modifying the downpipe... will the turbo be at the right height or do I need to do any other mods to make it fit?IE, to mount a k24, do I need the exhaust manifold it came with? A guy up the road from me has a k24 with its manifold

Also, are the k14 and T2 turbos commonplace? Bolt in would be preferable... The only reason I was leaning towards a k24 is there seems to be a few avilable from 1.6TDs.

[andy2]

Yes you'll need that manifold,intake air hose,the 90 deg hose from turbo to intake and oil drain pipe.A good condition k14/t2 may be harder to come by.The old k24,t3's always out lasted the engine.If you can get the k24 cheap and don't mind modifing a bit them go for if.

[addautomotive]

sweet! Maybe I'll take that route. I just went out and looked at the downpipe and I see what you mean about modifying it. Should be straightforward.

Weird thing about the compressor wheel on the turbo... looking at it closely it seems to have burned up, instead of being damaged by debris. Yoiks! Maybe I need to set up an EGT gauge.

[dieselweasel]

Just so you know, the wheel on the exhaust side is called the turbine wheel.

[addautomotive]

Thanks dieselweasel... I usually look stuff like that up before I post... lessens the chance of confusion.

Another question: I got the dieselicious bearing & seal kit from Jake Russel for my k03... are any of the bits useable on a k24?

[fspGTD]

Hi jake -

Hopefully you got my e-mail reply by now, and should have some info that will help you decide what to do about this.  That melted turbine wheel is crazy...   (very graphic picture- WOW! :shock: )

PS - Probably just water under the bridge at this point, but yes, an EGT gauge is definitely a good idea when increasing the fueling on a turbo diesel, to make sure temps are in a safe range.

[addautomotive]

Jake,

Thank you for your very helpful email. I've already opened the packages and had my greasy mits all over the bits & peices, so I'll just hang onto the k03 rebuild kit. My father in law has a 95 1.9AAZ, so he may need it eventually.

What are your thoughts on putting in a k24? I made a couple calls and there are 3 available locally with the exhaust manifolds. They seem much easier to put my mitts on, and sound like a nice improvement over the K03.

[addautomotive]

Good news: the exhaust manifold came off very, very easily.   I was expecting it to be much more difficult... broken studs etc.

Getting the manifold off was the barrier to putting on a larger k24. I figured I'd fight with themanifold nuts, give up and just put on another K03.

Instead, I'm on my way to a nice upgrade, methinks. As of 9:45 this evening, I have my pick of about 6 different k24s... so parts are going to be easy.

Question: :?: I don't know that I'll be able to get my mitts on an EGT sender before the manifold goes in, but I thought I'd at least drill & tap a hole for it. What size?

[DVST8R]

It will either be a 1/8npt or a 1/4npt, depending on brand, and style. Iirc all autometer are 1/8th and all the isspro that i have seen are 1/4npt.

[fspGTD]

Glad to hear the manifold came off of there with no issues.  That's also great you have readily available a supply of potential replacement turbos and manifolds.

It's a good time to surface the turbine inlet flange when the exhaust manifold is off, if you find that the sealing surface is warped or pitted.

Either of the 1.6lTD turbos (KKK K24 or Garrett) would be much more reliable for high performance application with the boost turned up than the K03.  At low boost levels (IE: stock) the K03 may be preferable, as it will spool up the quickest.  Only the K03 (or a VNT) is going to get you peak boost by 2000RPM in a quick-acceleration scenario.
 
An eco-diesel K14 is in between either of the larger 1.6lTD turbos (K24 or Garrett) and a K03 in terms of size, as well as in boost/airflow potential and also spool up time.

I believe you can make most high mileage and worn out turbos spool up quicker by rebuilding them, including hand lapping the wastegate valve seal to make sure when it's shut, no gas is getting by.  Hope this helps, and good luck!

PS - I used to run a 1/4"NPT EGT probe, but for my most recent thermocouple installation I opted instead for a smaller, 1/8"NPT size.  It seemed easier to find a good spot to put the smaller 1/8"NPT size.  Way to go with planning out a pre-turbine thermocouple location!