mk1 1.9TDI in progress

[mollins]

depending on what K04 you use, you would be pushing it at 25psi.

ps. remember my redline is at 4500rpm ..

therefore i need less air to keep the boost up.

[Greg Roles]

1Z or AHU (96-99 golf/jetta/passat) uses K03 or T15 i think. The K03 is the 12 blade compressor similar to the standard early 1.8T turbo.

the k04 i have is a cheapo chinese copy with a 2inch turbine dunno what model its copied from. I have also in the post a genuine KKK K04-003 from an izuzu 2.5 of which i hope to use the core only, along with the compressor/turbine housing from the chinese one. This will hopefully make me a frankenturbo which will bolt straight on but have genuine kkk components and not cost a million dollars.

neil, have you found any info on the -003?

i guess i'll see what happens when it arrives.

I'm loving the tinkering going on here.
You'd make Tim Allen proud.
"Frankenturbo" - love it.

[Volvo Driver]

ps. remember my redline is at 4500rpm ..

therefore i need less air to keep the boost up.

Our one revs out to 5, needs more power though, gotta convince dad to fit a decent bar and plate to it :p

Well cam plates and governor mods and spring are a bit more advanced mods then the max fuel screw and boost pin angle. Can't exactly change them without the pump off the vehicle. But yeah it does make it simpler.

[mollins]

Our one revs out to 5, needs more power though, gotta convince dad to fit a decent bar and plate to it :p

nice to know it will go to 5K.
yeah the stock coolers are tiny. would make a reasonable difference i reckon. Its a shame theres not much space in the front of a mk3!

Can't exactly change them without the pump off the vehicle.

that wont stop me!

[mollins]

ok.. so the story is.. i have a chinese turbo. its a K04 copy made by the reputable manufacturer "YEQI". Definitely my favourite brand!

anyways, its crap. So.. Aydan found a real K04 on the net for 300 bucks. so i bought it. Its a genuine 3K K04-003 from a chrysler 2.5.

here are the two turbos side by side




the problem is, that the turbine inlet on the new turbo doesnt match my exhaust manifold. so... we pulled off the turbine housings to see what we could see


here they are again side by side


They looked pretty similar, so all we had to do was swap the turbine housings!!

almost..

the problem was that the turbine blades were just a smidgen taller at the outer diameter on the 3K turbo, which meant the blades contacted the casing from the YEQI. so... we used the backing plate from the YEQI.. with a bit of modification:



we got this!



which when placed under the turbine housing, gave the perfect clearance for the turbine wheel!




a quick test fit:



then to mount the wastegate actuator. had to tap some holes on the 3K turbo. then:

[mollins]

its alive!!!!

FRANKEN TURBO:

[Jarred]

Nice one. Hope it all holds together! Wouldn't want to see half a turbo flying through the bonnet...

well, a small part of me would, but that's for another day

[smithy010]

That would be well wicked!

Note to self: Carry video camera wherever you go..

I have total faith in Mike and Aydan's Franken turbo expertise.

[GoLfMan]

nice one mate, as Jarred said i hope that housing is good quality
you guys are the ultimate DIY's!!

[gldgti]

I have total faith in Mike and Aydan's Franken turbo expertise.

admittedly, there is no exper(ience)tise to be had here... but both of us are mechanical engineers, and both of us agreed that there should be no reason for anything bad to happen.

FAMOUS LAST WORDS