So I bought a rebuild kit for my K03 because it had shaft play and was a potential culpret of the large amount of oil in my intake. Upon disassembly of the turbo I noticed some problems that the rebuild kit wouldn't fix. I'm on somewhat of a tight budget, so I'd like to only replace what's absolutely necessary. Let me know if you guys think I can get away with not replacing some of these parts. Also if anyone knows where I can find a used K03 for a 2001 AWM engine code for under $100 that would be helpful too. Yes I've checked the classifieds and will continue to do so.

Figured replacement of the exhaust flange is a no-brainer, but thought I'd show you guys the extent of the damage anyway. Are all the exhaust flanges for the 1.8t longitudinal K03 the same?


The tip of one of the compressor wheel blades is chipped. How much would this affect the balance or performance of the turbo?


Failry large chunk taken out of the end of the turbine end of the shaft. I'm assuming this was done intentionally for balancing?


Some slight scoring of the inside of the compressor housing (probably from some very small debris). Is it worth my time to sand/polish all this out? I know replacement is probably unnecessary.


This ring was completely out of it's groove and covered in sludgy oil. Is this the reason I've had dirty coolant for the past few years? I know the ring gets replaced, but I'm hoping the shaft won't need to be.


Sludgy oil and sludgy coolant caked onto another part. I know this doesn't need to be replaced, it's just dirty


Sludgy coolant. Rebuild kit came with a new one of these, so it's getting replaced.

 

If the blades made contact with the housing, you need a new wheel and to have it balanced. Also, most used turbos are about $150 on vortex.

 

Not what I wanted to hear, but thanks for the info. I know that ideally I should get a turbo off another 2001 AWM, but what if I can't find one cheap enough? Can I use the turbine wheel/shaft and compressor wheel from an older turbo? or are there differences in dimensions or amount of blades? I seem to find a lot of conflicting information pertaining to the differences in our turbos.

Also what should I expect to pay for balancing if it has to come to that?

 

It just needs to be off a passat or a4. What engine code won't make any real difference. Vwvortex is usually a good place to find one.

 

Cool, thanks. Balancing won't be necessary if I use the shaft, turbine wheel, and compressor wheel all from the same turbo, right? Of course I'll mark both wheel's relation to the shaft prior to disassembly and reinstall them the same way.

 

It wouldn't, but I would just buy a decent used turbo. They aren't that expensive

 

Not a bad idea as the individual parts probably aren't much cheaper. I just found a used K04-015 that I'm going to try to take a look at soon. Anything I should be checking for other than cracks, leaks, damaged blades, and shaft play?

There are also two things I heard that will identify this turbo as a genuine Borg Warner K04-015. One is a blue ID plate riveted onto the compressor housing that I'm assuming will have a part number that begins with K04-015, and the other is the number 5304 101 50 61D embossed on the compressor housing. Is all of this true?

 

The K04 I was interested in turned out to be just another K03, but luckily enough I just had a K03 off another 2001 A4 given to me. Everything seems to be in great condition except for the exhaust flange. This too has a crack in the same place as the one seen in the first pic I posted. It doesn't seem to have any other cracks though, so it's in better shape than the one that came off my car.

Are most of these turbos cracked? How hard is it to find one that isn't?

 

The cracks seem to be normal and not a problem. Even the transverse models get them. As long as it's not leaking, it's good

 

That's a relief. Looks like I can finally start putting my car back together.