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> Kkk Turbo Strip/rebuild.
Brian.G
post Jan 15 2009, 07:55 PM
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said ide throw it up, may come in hand for someone...
right here it is, first thing, remove the outer 10mm bolt on the actuator shaft
(note this is from my 1.8t, a6, ko3 type)
(IMG:http://i150.photobucket.com/albums/s92/chippievw/kkkturbo001.jpg)
mark with something sharp the relationship between the housings and the main body so it will be easy to get the positions right when putting them back as they can be fitted anywhere in relation to each other.
(IMG:http://i150.photobucket.com/albums/s92/chippievw/kkkturbo002.jpg)
next youll see the securing clamps holding on the hotside, DO NOT try and open the bolts with a 10mm spanner as you WILL round the heads, instead with a punch or screwdriver knock the holding tabs around to loosen the bolts.
(IMG:http://i150.photobucket.com/albums/s92/chippievw/kkkturbo003.jpg)
unscrew the bolts a bit at a time, at least two boltheads will come up against the exhaust housing, this is a good thing as they will press off the housing for you as they can get tight. heres what youll be left with.
(IMG:http://i150.photobucket.com/albums/s92/chippievw/kkkturbo004.jpg)
next, with a ten spanner open the four bolts holding on the cool side compressor, refit bolts again as you will need them there for the next step.
(IMG:http://i150.photobucket.com/albums/s92/chippievw/kkkturbo005.jpg)
its important at this point to be very careful of the turbine blades, not alone are they sharp but they are very easy to damage.
with a tiny bit of paint in a pointer mark both the wheel and the axle to be sure they are refitted in exactly the same spot, its a balanced unit after all. its hard to see paint on shaft but if your at it yourself youll know what to look for.
(IMG:http://i150.photobucket.com/albums/s92/chippievw/kkkturbo006.jpg)
the next step is to warm the alloy housing a small bit with a torch, just around the rim will be fine.
now with a lever or screwdriver, lever up the unit from the housing, use the bolts as fulcrums and do it evenly, the housing will now pop off.
(IMG:http://i150.photobucket.com/albums/s92/chippievw/kkkturbo007.jpg)
at this point the nut on the cool side can be loosened, hold the hot end with a 10mm socket and undo the nut, its a ten mil, and is a LEFT HAND THREAD. the impeller will pull off.


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Brian.G
post Jan 15 2009, 07:56 PM
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(IMG:http://i150.photobucket.com/albums/s92/chippievw/kkkturbo008.jpg)
remove alloy shield, it will come up with light pressure.
(IMG:http://i150.photobucket.com/albums/s92/chippievw/kkkturbo009.jpg)
now start pulling up the seals, and bushings, keep them in order or take a pic as you take them off.
(IMG:http://i150.photobucket.com/albums/s92/chippievw/kkkturbo010.jpg)
you will only get so far before you have to remove the circlip, remove it.
(IMG:http://i150.photobucket.com/albums/s92/chippievw/kkkturbo011.jpg)
after its removed, pull out main shaft from the far side, it just slides out.
at that point the spacer and main bush can be removed, push main bush up to yourself from below it just slides out.
and heres what you should be left with, all in order, the next steps are to clean everything, and refit/inspect seals and bushings for wear, ill be fitting new bush/seal kit when i have everything cleaned up.
(IMG:http://i150.photobucket.com/albums/s92/chippievw/kkkturbo012.jpg)

i hope this may come in handy if someone wants to give it a shot at doing there own, enjoy!


--------------------
''People are always blaming their circumstances for what they are, I don't believe in circumstances, the people who get on in this world are the people who get up and look for the circumstances they want, and if they cant find them, make them''

Destruction, Fire, Danger, Creation.
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PaudieG60
post Jan 15 2009, 08:16 PM
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Very well done Brian! Didnt realise ko3's needed to be rebuilt!! Wheres the week point of these turbos?


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Brian.G
post Jan 15 2009, 08:19 PM
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all turbos that have miles done benefit from a rebuild, i did mine as the engine had been starved of oil, i want everything right when finished so i dident want to take any chances with the turbo (IMG:style_emoticons/default/wink.gif)
heres what the rebuild kit looks like/contains
(IMG:http://i150.photobucket.com/albums/s92/chippievw/c5cc_1.jpg)


--------------------
''People are always blaming their circumstances for what they are, I don't believe in circumstances, the people who get on in this world are the people who get up and look for the circumstances they want, and if they cant find them, make them''

Destruction, Fire, Danger, Creation.
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babyface
post Jan 15 2009, 10:27 PM
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Good man Brian, will be sorting my own k03 as soon as the weather gives me a break (roadside mechanics sucks this time of year!)

(IMG:http://www.gpopshop.com/kkkkitweb.jpg)



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jayc20xe
post Jan 15 2009, 11:05 PM
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Handy, just about to do mine just waiting on the kit to arrive.

Very useful reference, well done.

Maybe a weekly slot for ya, gearbox rebuild next !!!!!


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The Nordschleife 22km of pure adrenaline - Green Hell!!!!
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Brian.G
post Jan 15 2009, 11:15 PM
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thanks james, waiting on the kit myself, had a few partial kits here i thought ide be able to make up what i want for the k03 but no parts match! ill be doing a part 2 rebuild guide when i get it. (IMG:style_emoticons/default/wink.gif)


--------------------
''People are always blaming their circumstances for what they are, I don't believe in circumstances, the people who get on in this world are the people who get up and look for the circumstances they want, and if they cant find them, make them''

Destruction, Fire, Danger, Creation.
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conord
post Jan 16 2009, 12:12 AM
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its pronounced Conor D........... Ray!!!
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very interesting write up brian.

lookin forward to part 2 (IMG:style_emoticons/default/laugh.gif)


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QUOTE (Razor)
so Conor when u get sad do u just stop being sad and get Awesome instead?

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Vdubs69
post Jan 16 2009, 09:19 AM
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Good job with the guide lads, I dont even have a 1.8T and I feel like i wanna do it (IMG:style_emoticons/default/laugh.gif)
Question tho, I got a mate with a Mk4 1.8T and engine would of done around 90k, Is this something that should be done to improve the Turbo or how would you know when this work needs to be done?
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Razor
post Jan 16 2009, 09:49 AM
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man i wanna buy a cheap turbo and give that a shot!!!! sad i know lol!!!
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joesoap
post Jan 16 2009, 10:26 AM
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Great topic Brain (IMG:style_emoticons/default/wink.gif)


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1982robw
post Jun 9 2012, 02:16 PM
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is there a part 2 with the rebuild?
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