Author Topic: kkk rebuild kit (Read 5579 times)

jolotter · « **on:** May 29, 2007, 08:10:54 pm »

I just got my k24 rebuild kit in the mail today. I can't believe all the parts that came in it, including all the bolts and such. I guess I'll cut of the heads of the wastegate bolts to get it off since I only ended up rounding the allen heads even with lots of liquid wrench and my torch! I was just going to leave it, but no longer. Grin.
It's a genuine Borg Warner Made in Germany kit.
Her's pics and ordering info. The guy's name in Wayne. It cost $105 inc. tax and shipping and took one day to get here.

If anyone has tips for those wastegate bolts, I'd like to hear them.

jolotter · « **Reply #1 on:** May 29, 2007, 08:27:10 pm »

Maybe someone here can help me with identification of a few of those parts.

What are the large copper washers? They have a slichtly rounded face on both sides and are the same diameter as the spindle bearings.
Two piston rings are black, two silver. Do the black ones go on the exhaust side?
The banjo bolt washers. Two are copper and two are silver (steel?) I noticed that when I took them off but figured that someone had used the steel on one instead of copper adding to the copious amount of oil everywhere. I neglected to note which were which. Does the copper go to the steel wastegate or the aluminium compressor housing?

The only part that did not come in that kit is the large brass washer behind the thrust bearing. Hmm.

Johann

Kudagra · « **Reply #2 on:** June 06, 2007, 06:50:16 pm »

Some of the Audis run a water cooled turbo. Those copper washers might be for the water lines.

Id have to tear into one to know the rest. Its been a few years.

jolotter · « **Reply #3 on:** June 06, 2007, 08:17:04 pm »

So I've finished my turbo rebuild. Those spare parts were indeed for a different application.
The turbo spins freely now whereas before it was a stiff turn. I think it was mainly from the carbon in and around the groove of the oil control rings on the exhaust side that was causing the drag. However all new parts sure helps me sleep easy
The new allen bolts for the wastegate allowed be to cut one head off and destroy the other two in disassembly. I cleaned it up and ground the seat but otherwise it was working fine.
The kit does not have the large brass washer behind the thrust bearing or the smaller bushing that rides the centre it. Wayne at ADP said they are no longer available.
Anyway, great kit for your k24

jolotter · « **Reply #4 on:** June 06, 2007, 08:21:25 pm »

I also deduced that for the banjo bolts, the copper go on the cast iron wastegate fitting and the aluminium ones go on the aluminum compressor housing. There should probably be one aluminium and one copper for that side as the other side of that fitting is steel to steel.

Oilheat · « **Reply #5 on:** June 11, 2007, 07:57:20 pm »

Everything fit fine? There was a previous thread about rebuild kits for the k24 which stated that the VW application actually used the center section pieces for a k26, but not the orange o-ring for the compressor scroll.

Oilheat · « **Reply #6 on:** June 12, 2007, 10:20:17 am »

Johann, thanks for the good pic with the part number and seller info.

I called my regional Borg Warner distributor here in New England, D&W Diesel in Auburn Mass., and they had no clue, said they did not recognize the number and would have to order from Germany.

So I called Wayne at ADP and got his last overhaul kit, $68 USD, plus shipping. I even used the tollfree phone number from the top of the invoice!

jtanguay · « **Reply #7 on:** June 12, 2007, 01:22:07 pm »

well i got the turbo motor pulled from my parts car finally... and the turbo actually looks in half decent condition... I wouldn't mind trying to rebuild it though!

those thrust washers aren't the full 360 degree ones that Jake was selling... any idea where he was getting his from??? I can see some benefits from his type such as... if you were to hit a big bump while blasting... the turbo wouldn't smack the housing :oops:

jolotter · « **Reply #8 on:** June 12, 2007, 09:16:51 pm »

Oilheat,
All the parts fit perfectly. The only trick was coaxing the turbine shaft into position on the exhaust side without damaging the piston sealing rings.

jtanguay, i don't know where Jake got those 360 thrust washers, but when I disassembled my turbo, although the PO had rarely changed the oil and I could only turn it by hand with difficulty, the thrust bearing had some light scoring only. It did not seem that it was suffering undue wear.
The whole job was straightforward and only required my modifying one tool, my dollar store snap ring pliers, as the one circlip is quite deep in the housing on the exhaust side.