k03s to a k03s (k04) internal hybrid

[koolben19]

hey all fairly new here
i have a 2003 leon curpa which i understand has a k03s turbo on
now the turbo has leak and fumes leaking from the turbo and also sucking **** loads of oil outta engine. i heard i can get it k04 internals put in this no i rele need it done as currently carless
can anyone help as info would be greatly appreciated
cheers ben

 

[Phillc]

Thats a hybrid Turbo, not something you can do your self, look on Badger5's page HERE.

 

[koolben19]

yea they charge a lot i been quoted 450 to get it done now cheers

 

[T108]

Thats a hybrid Turbo, not something you can do your self, look on Badger5's page HERE.

Cant I??

So not done alot recently so i decided it was time to build a suitable replacement for the k03 that's done 130k

did some research into the kkk series of turbos and found that the k03 and k04 range share many parts in common enough to build a hybrid from standard parts.

So

Sourced a low mileage k03 as a doner:

Stripped and rebuilt it with genuine bearing kit and k04-22 compressor wheel and backplate
this picture shows the difference in compressor size:

Core built up turbine not visible as its sat inside and aerosol lid, compressor housings cut ready to be tigged

Assembled Core has been VSR balanced by CRturbos in newmilton excellent service same day turnaround

Fitted back into exhaust housing:

Just waiting for the k04-22 compressor housing to be tigged up with the outlet of the k03 housing hopefully will be done next week

Compressor housing welded and turbo fully assembled

standard Vs Hybrid

 

[koolben19]

Eh ?

 

[Phillc]

Cant I??

Not easily no as you have shown.

 

[towcester vag]

the turbo has to be balanced!
yes you can do yourself but if its not balanced you run the risk of it letting go when its spinning at 20000rpm and you doing 6000rpm
Not a nice combination!

 

[ibizacupra]

Cant I??

there are a couple of features on the k04 comp housing which need to be removed to fit onto k03 manifold.. as per lupo hybrid+ thread in my section.

to me I prefer the k04 comp cover hybrid version as its got a bigger inlet... BUt with that brings its own fitment TIP issues.. Solveable of course

 

[T108]

Yep thats what i have done, used a modified K04-22 compressor housing with the lumps that get in the way ground off, and the corner of the head ground for clearence. as per Bills Lupo k03 Hybrid+ Thread (where the inspiration came from to be honest) Made up a custom TIP

And Yes I had the turbo Balanced im not an idiot

Have been running this hybrid for over 2 months now with no problems, love the way it spools and keeps boosting at high revs.

 

[n1ff]

Sorry to hijack, are there any recommended exhaust manifolds? Am I wrong in thinking these are the ones prone to cracking?