RobDon
21-09-2004, 12:29
Found this thread on VW Vortex: http://forums.vwvortex.com/zerothread?id=1598145
They appear to have a K04-023 turbo (same as LCR) with K03S modified exhaust housing mated to a custom manifold, very interesting reading and could potentially be a very good upgrade for the non-LCR 1.8T brigade who are sick of waiting for big turbo kits.
http://www.ittelecomhellas.com/images/DSCN0357.JPG
http://www.ittelecomhellas.com/images/DSCN0364.JPG
Quote: "Ok, guys I just wanted to let you know that we have just finished the installation of the K04 turbo today. Tomorrow the car
will be going for the 3 inch turbo-back exhaust system and have already ordered a 3 inch MOROSO SPIRALFLOW MUFFLER/RESONATOR.
This will be fitted together with a rear muffler because I want the car to sound nice, but not too loud.
I just thought that I should give you a little more information about the turbo that I am using. I have been reading a lot of scare
stories on the K04 and K03 modified turbo's. I have been talking at length with my tuner on the issue of the KKK K0x series reliability
and this is what he had to say:
KKK K0x series turbos fail for the following reasons:
1. Overspeeding by very aggressive, inefficient boost curves
2. Torsional inertia vibrations from mismatched compressor and turbine wheel gas flow capabilities
3. Hybrid turbos built by "remanufacturers" that do not have, or do not use turbo assembly High Speed Balancing equipment. (Both
compressor wheels and turbine/shaft assemblies come individually balanced from the factory but require further balancing when they are assembled together)
4. Poor maintenance, hot shutdown and long oil change intervals.
The turbo is actually a standard issue K04 -023 for the AUDI TT, AUDI S3 and SEAT LEON CUPRA R. In order to fit the stock K03
exhaust manifold, the K04 exhaust housing is removed and a special part number K03S exhaust housing is used. This has the largest
turbine scroll volume that fits within the standard K03S exhaust housing casting. This housing is not normally used for production cars
because VAG wants the fastest response time and the lowest RPM for maximum torque. Don't ask me for part numbers because I did not get
any... But he did say that the difference between castings can only be seen by the computer inkjet part number that appears on brand
new housings, or by sawing the housing in half.
The housing has to be machined to accept the bigger diameter of the K04 -023 turbine wheel diameter. The compressor outlet of a
non-silenced K03 is fitted on the compressor scroll of the K04.
To answer your question, yes you could machine your own K03 housing to
fit the K04 turbo assembly, but you will have a smaller A/R ratio and smaller scroll volume than the K04 -023.
If you do that, you will have less horsepower than a full K04, but it will bolt on without anymore expense."
They appear to have a K04-023 turbo (same as LCR) with K03S modified exhaust housing mated to a custom manifold, very interesting reading and could potentially be a very good upgrade for the non-LCR 1.8T brigade who are sick of waiting for big turbo kits.
http://www.ittelecomhellas.com/images/DSCN0357.JPG
http://www.ittelecomhellas.com/images/DSCN0364.JPG
Quote: "Ok, guys I just wanted to let you know that we have just finished the installation of the K04 turbo today. Tomorrow the car
will be going for the 3 inch turbo-back exhaust system and have already ordered a 3 inch MOROSO SPIRALFLOW MUFFLER/RESONATOR.
This will be fitted together with a rear muffler because I want the car to sound nice, but not too loud.
I just thought that I should give you a little more information about the turbo that I am using. I have been reading a lot of scare
stories on the K04 and K03 modified turbo's. I have been talking at length with my tuner on the issue of the KKK K0x series reliability
and this is what he had to say:
KKK K0x series turbos fail for the following reasons:
1. Overspeeding by very aggressive, inefficient boost curves
2. Torsional inertia vibrations from mismatched compressor and turbine wheel gas flow capabilities
3. Hybrid turbos built by "remanufacturers" that do not have, or do not use turbo assembly High Speed Balancing equipment. (Both
compressor wheels and turbine/shaft assemblies come individually balanced from the factory but require further balancing when they are assembled together)
4. Poor maintenance, hot shutdown and long oil change intervals.
The turbo is actually a standard issue K04 -023 for the AUDI TT, AUDI S3 and SEAT LEON CUPRA R. In order to fit the stock K03
exhaust manifold, the K04 exhaust housing is removed and a special part number K03S exhaust housing is used. This has the largest
turbine scroll volume that fits within the standard K03S exhaust housing casting. This housing is not normally used for production cars
because VAG wants the fastest response time and the lowest RPM for maximum torque. Don't ask me for part numbers because I did not get
any... But he did say that the difference between castings can only be seen by the computer inkjet part number that appears on brand
new housings, or by sawing the housing in half.
The housing has to be machined to accept the bigger diameter of the K04 -023 turbine wheel diameter. The compressor outlet of a
non-silenced K03 is fitted on the compressor scroll of the K04.
To answer your question, yes you could machine your own K03 housing to
fit the K04 turbo assembly, but you will have a smaller A/R ratio and smaller scroll volume than the K04 -023.
If you do that, you will have less horsepower than a full K04, but it will bolt on without anymore expense."