ko3s install problems

[cupramillo]

Took my car to my local VAG specialists (mastertechs) and they are having real issues getting the work done. The mechanic said that they are having problems with getting it to fit to the waset gate, i dont know much about it myself. Emailed him a guide i found

http://forums.vwvortex.com/zerothread?id=2296520

wondering if there was a different guide that anyone else used that made it easier to follow.

any ideas?

 

[truCido]

the KO3s wastegate is different to the KO3 wastegate....there not trying to use the KO3 wastegate on the KO3s are they??

 

[cupramillo]

does that mean i'll need a new waste gate? yeh i think they are but he said it wouldnt work

 

[cupramillo]

bump

 

[Reuvers]

wastegate...is that the opening of the turbo where it meets the TIP?
If yes, then you need a silicone aftermarket tip.

Your regular K03 has a small wastegate port, where the tip comes on. Your original TIP (turbo intake pipe btw which is the black hose in which your dumpvalve sits, and on the other end your MAF and airfilter) has a metal casing on the bottom which fits perfectly on your K03 wastegate.
BUT because the k03s has a larger wastegate in diameter, the metal part of the TIP does not go on the wastegate!
Therefore you need a silicone TIP which due to it being silicone can stretch over the larger wastegate!

tell them not to try and force the original tip on your new turbo, and get yourself a TIP!


btw really hope the waste gate is what i think it is or I described somethign completely different lol

 

[cupramillo]

thanks for the reply, i already have a forge tip. Yeh i think you have the right meaning of the word waste gate. They mechanic keeps saying "its far from a straight turbo swap and a real bugger of a job". But the main thing he is saying is that he can get the ko3s to fit the waste gate. I dont have a clue to be honest. I sent him the guide i found on here, so will see what happens. Should the ko3s i bought have had the new wastegate already on it? Im going nuts

 

[Reuvers]

Ok the thing I am talking about is this:

If its that, then they need to spray on a little wd40. slips on then. Its a bitch to do I know, but have one of them under the car guiding it and the other from above pushing it on. He needs to stand infront of the car and with his right hand push it on!
If they aren't absolute clowns they should manage!

I have heard though that sometimes the TIP is slightly too long there so you need to cut a bit. BUT have them be sure, because you can't put the cut piece back on afterwards

 

[cupramillo]

i might sound like a total muppet, but is the waste gate on the turbo itself or on the engine near the turbo?

 

[Reuvers]

again, if its what I think it is and showing in the pics then its a part of the turbo, and not changeable

 

[cupramillo]

thanks for the help. Im not sure to be honest. They are a really good garage but they have had the car sice monday, and still seems like no progress has been made. I thought if anyone know these engines it would be master tech meahnics. And from what i have read on here its seems straight forward enough, i bought the turbo and the fitting kit, nuts, washers, gaskets etc but still they cant fit it.

Going to give the guy the weekend to read the guide, if there is no progress by weds im going to tell them to put the standard turbo back on and take it some where else. Just want my car back!

 

[Reuvers]

yeah I understand.

I'm just waiting untill someone confirms that what I think is the wastegate is correct. If so, then you really need to kick those guys off the azzes or take your car elsewhere

 

[-pseudonymous-]

Do they mean the actuator? The wastegate on the ko3/ko3s is internal. Its a little flap that is connected to the bar on the actuator which opens and closes to control the boost.

Are they having trouble physically fitting it or just plumbing it in? Just a thought because the ko3's actuator has 1 vac port whereas the ko3 has 2 so the original vac line will need to be blanked off. You know that right? Cant see what else could be the problem because its like for like....

 

[Reuvers]

damn I am gonna feel real emberrassed if all I posted is not the wastegate lol!

as said though there is indeed only 1 vac pipe coming off acurator as mentioned in guide.

Only other thing I could think of, is that I bought a new one for a TT and i had to undo the 5 (or so) bolts on the side of the turbo and turn the two parts of the turbo 1 bolt hole further, to have the charge pipe connection line up properly

 

[cupramillo]

yeh it could be that, he said something about a little piston or something? Yeh its the plumbing in they are having issues with. What does it have to be blanked off with?

thanks for the input all

 

[Reuvers]

I'm talking about the 4 bolts just above/to the left of the red plastic cover in the below pic:

that lets you twist the 2 parts

 

[DaNnY_LaD]

A k03s has one Vac Pipe on the actutor and a k03 has 2 on the acutor

Have u done the N249 bypass?#

It will bolt straight on!!!! Some vag specialist he is...

 

[h17och]

mate...if you have taking it to a vag specialist and they cant even do a k03s swap then i would want my car back asap and tell them to forget it.

how much they charging? i will fit you a k03s for 100quid. no problems done in a few hours while you wait. im just north of watford

HoocH

 

[Reuvers]

ok on the K03 there is 3 vac lines running to it in total. 1 to the far bottom, just next to where the TIP comes on the turbo.

then another one on the acurator which is the copper looking UFO thing in the above picture at the top (you can just see the small nipple)

And then another one.


That last one you need to block off. The K03s no longer has a opening for that.

just run that vac line to the beginning (might be a T piece not sure anymore) but block it there

 

[DaNnY_LaD]

mate...if you have taking it to a vag specialist and they cant even do a k03s swap then i would want my car back asap and tell them to forget it.

how much they charging? i will fit you a k03s for 100quid. no problems done in a few hours while you wait. im just north of watford

HoocH

What he said.!!!

or you could do it your self in a day

 

[Reuvers]

as Hooch says, let him do it. I do this here in the Netherlands too for others.