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Discussion Starter · #1 ·
Hello all,
I while reinstalling the head on my daughter's 2002 1.8l glx beetle and took many photos of the process. Zooming in on one I found a crack in the turbo. Advice? Has anyone had success welding or having a turbo welded? In a previous life I welded on machines, but not cast iron, too tricky. I do have a welder I use from time to time.
Thanks Tom
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This is a classic issue with the k03/k03s turbochargers; it seems, after a certain amount of heat cycles, they crack or sometimes, the auxiliary waterpump, that cools the turbo, might fail and contribute to this issue.

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I did a head job on a 2001 Audi TT with the AWP 1.8T and when I removed the head/exhaust manifold, it was cracked in the EXACT same place, on the hot side of the turbo.

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On another K03 Turbocharger; from a 1997 Audi A4 1.8T, the crack was in the same place also.

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The Audi K03, had low boost issues; once the turbo came off, it was apparent, that the wastage was loose/worn and there was a crack on the sealing area, causing a boost issue.

So, I have seen this on two 1.8Ts; that I have worked on and on the web, it seems to be a known issue. In the case of the Audi A4, the crack, looks like it went through the whole casting and cracked at the wastage as well. I can only assume on the Audi TT; it was going to keep traveling and @ over 100k, 20 year old car, the turbo was going to go eventually and so, we recommended to the customer, to get a new one. We researched the rebuild route and the rebuilders; mentioned the cracking issue but didn't have extra castings and researching the web, there seems to be cheap Chinese replacements.

The customer, was going to keep the car long term and love it, a Audi TT convertible, felt he was willing to spend the dough. We found a genuine Borg Warner oem turbocharger from FCPEURO and they offer a lifetime warranty, on any parts they sell, so that seemed to be the best solution, highest quality part, warranty for life.

Because, of the crack prone nature of the k03s and the fact, we had seen the crack travel to the waste gate, we felt, that was the wisest solution for a stock turbocharger. As you know, it takes quite a bit of time and effort; to get the head off and that is the best time, to access the turbocharger. After a rebuilt head, timing belt kit, new turbocharger and gaskets, typical replacement tune up parts, coolant, oil, filters, etc, etc, the bill was $4k+, when it was all said and done. Thankfully, everything went according to plan; the engine started right up after reassembly; the lifers quieted down after warm up and the new turbocharger, really helped the boost and the car ran perfectly! A happy customer and it is his baby, so he was happy to have to fixed.

I'm not a welder, however; that nature of the castings and how we have seen, the cracks travel through the casting to the waste gate sealing area, replacement would make sense.

The customer wanted a stock turbo but if this is your case, it could be a opportunity to upgrade to a ko4 or a "hybrid" modified k03/k04 setup or go bigger, where only your imagination and pocketbook limits your choices.
 

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Discussion Starter · #3 ·
It does make you wonder how much you love your bug.
I was going to pull one, if I could find one, from the local 'pick and pull', but it sounds like they all will crack in time and who knows what abuse those cars have been through. The bug is running well at the time and is not on the highway or even far from home. So I will wait and address this as it becomes a problem.
Besides a slight leak from the coolant pipe from the block to the transmission cooler, I have ordered a new line, and a mysterious vacuum leak this bug is back to life. Thanks again for the advice, again,
Tom
 

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I would say this is the time to address the turbo; if you are keeping the car and want it to be reliable long term (especially, for your daughter). Swapping out the turbos is MUCH easier with the head off; rather than with it on.

In a attempt, to keep costs low; a used turbo could be a option or shipping one out for a rebuild, is a thought?

From a cost effective perspective; a new turbo, may not be much more?

Fcpeuro, has a genuine Borg Warner k03 with a lifetime warranty in the $500-$700; depending on which turbo you need (regular k03 or the updated K03s).



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Discussion Starter · #5 ·
Thanks for the link, and this a lot cheaper than I thought.
If possible, I was going to remove the hood and the exhaust manifold without pulling the head, I just got it on. Has anyone else attempted to put on a turbo without pulling the head?

I am having a bit of difficulty determining which turbo will fit my bug. The link that was in the last reply the turbo looks spot on. The intake tube is straight down without change, however, the site (Genuine and OEM Replacement Car Parts Online | BMW Volvo Audi VW Mercedes Porsche Saab | FCP Euro) is pointing me to a turbo that is very different based on my year, does anyone know of how to look it up by vin. Is there a site where you can punch your vin in to find VW numbers? Borg Wagner's site allows for OEM numbers but did not recognize anything I found on VW's site. Or would both work? K03 vs K03s is a mystery to me. I have a 2002 1.8l glx, or I might be missing something.
Again thanks. 500-600 is in my range. $1500 was not.

Happy new year,
Tom
 

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You can id the turbo by a badge riveted on the housing; it will have the vw and oem part # on it.

The other way is to contact Borg Warner or the vw parts site with your VIN # or contact your local vw dealers parts dept.

www.parts.vw.com


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Discussion Starter · #7 ·
Thanks, mirror in hand I am headed to the car. I did email FCP Euro with the vin. I was thinking that someone could have swapped the turbo in a past life of the car. The odometer was off by 30K which I was told when I bought it 5 years ago.
 

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Using a smart phone; is a easy way, to snap a photo of the id badge on the turbo.

Good info here:



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Discussion Starter · #9 ·
I beginning to think my car is a Frankenstein.
I heard back from FCP Euro and the one that they said matches my car'a vin, most likely won't fit. I got the number from the casting on the one on the car now and emailed them back.
Thanks again,
Here are the photos for your interest. I just happen to notice that I had the number on a photo I took in December.
 

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Discussion Starter · #10 ·
I must love my daughter,
The Turbo is not available from FCP Euro at the time and the one I had was the original, just the new version looks somewhat different. So we are now looking around.
Suggestions of other places to order a turbo, I am coming up with well over $1200 for a rebuilt?
Tom
 

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The reason i mentioned fcpeuro; is the lifetime warranty and excellent customer service.

Once you nail down the right turbos; there are many other online vw parts specialists but without the lifetime warranty, i think BW has a one year warranty?

Here are some parts places; popular for VW parts:

. Largest Car Part Warehouse | Replacement Auto Parts Online | AutohausAZ


OEM / Performance / Maintenance / Repair / Replacement Parts and kits for Audi, BMW, Mercedes Benz, Mini, Porsche and Volkswagen | ECS Tuning (buyer beware; customer service can be lacking, long ship times or incorrect in stock info, poor packaging, etc), many customer consider ecstuning the one you “love to hate”, etc. YMMV!

Amazon

Rockauto, etc.


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Once, you figure out the vw part # and then, cross reference it with the oem genuine Borg Warner supplied new turbo kit (or double check by contacting them), it is just a case of finding it in stock and from a trusted supplier.


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Discussion Starter · #14 ·
I got the number straight off the old turbo and it is the original. FCP Euro were great at looking it up, and matching it to a turbo that they do not have currently or have a date of when they are going to be able to get one. I ordered through Cardinal, but the install kit from FCP Euro. Thanks again, my Frankenstein car may be more original than I thought,
Tom
Ordered.
 

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Hey, because of the crack in your original turbo; I would highly, recommend, you replace your auxiliary waterpump, as a preventative measure. This pump specifically, cools the turbocharger and this, would ensure, you new one lasts longer, is cooled, as it should be. Many pumps, are not running, without the owners realizing it or intermittently, turn on, then stop working or are not pumping, the coolant at the flow rate they should be.

Bosch part # 392020024 Electric Water Pump


 

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Discussion Starter · #18 ·
Thanks, I go my turbo a couple of days ago and getting ready to put it on. I still waiting on gaskets from FCP Euro.
I will order this as well and new banjo bolts and seals.
Question: I am using a Haynes manual, and it says the manufacture (Volkswagen) recommends replacing the "turbo/exhaust manifold" as a unit. I have had my exhaust manifold off when I put on the head. What are they asking for?
Does anyone know where I can get diagrams of breakdowns on this car? I am used to working on motorcycles where I have an exploded view of everything, even units.
Thanks again,
Tom
 

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The Borg Warner kkk03 turbo assembly and exhaust manifold are separate parts; i am not clear, as to why they would say to replace it, assuming it is in usable or good condition and also not cracked or damaged, etc.

I am not aware of the stock exhaust manifold; having any issues, like cracking or heard anyone needing to to replace them (normally) and all the 1.8Ts with a k03, that i have worked on or replaced, were fine (replacement is typically for a higher flow performance version).

Haynes and Chilton manuals; are better then nothing but no where near the factory VW eRWin or Bentley Publishers manuals (to put in motorcycle terms; comparing a .Clymer manual to say a genuine Honda/Yamaha/Suzuki, factory service manual)
 

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For real VW factory level service manual info; you would want the Bentley or the best, being the VW online service “eRWin” manuals; provided by VW and those are the same used by the VW service techs @ the dealerships. You can join for 24 hours access and download any manuals you need.


Here are some free online accessable vw factory service manuals:


Free downloadable VW eRWin manuals in .pdf. You might see; if your needed manuals are available here.


AllData and Mitchell1 offer consumer level access online; to one specific car as well and they are topically just licensed versions if the VW factory service manuals .

For parts info and diagrams; check out:

VW’s parts site:

www.parts.vw.com

ELSA/ETKA VW parts catalog used by dealerships:



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