KO3 Turbo, Warranty and Installation Info:
Updated Parts list, 97-99 Audi A4 1.8T
K03 Turbocharger Warranty Information
Turbochargers are often damaged by many "external" factors
that have nothing to do with the integrity of the Turbocharger itself.
The use of a modified Engine Control Unit (ECU) voids the turbocharger
warranty because it alters the factory boost profile and the Engine
Control Unit timing and fuel settings. Boost hose leaks, bypass valve
failures, or failure of the turbocharger boost control system can cause
the turbocharger to spin at excessively high speeds which can damage
the turbocharger.
Incorrect air/fuel mixtures, and/or timing settings can cause exhaust
temperatures to climb excessively that exceeds the manufacturer recommended
operating temperatures. Foreign objects in the intake or exhaust side
of the turbocharger can damage the turbine or compressor blades and
cause turbocharger failure.
The turbocharger must be supplied with clean oil of the correct specifications
and under the correct operating pressure as dictated by the manufacturer
requirements.
Turbochargers that are damaged by any of the aforementioned "external"
factors will void the manufacturers turbocharger warranty.
Turbochargers returned for warranty replacement should include a copy
of the original sales receipt, along with the sales receipt for the
additional turbocharger installation parts required by the vehicle manufacturer.
The returned turbocharger will first be inspected by an authorized 3K-Warner
Turbosystems remanufacturing facility to determine what caused the damage
or failure before any replacement turbocharger(s) are issued. Please
allow 2-3 weeks for this inspection process to be completed before any
warranty replacement turbocharger is returned. Warranty is limited to
the repair or replacement of product deemed to be defective at the sole
discretion of the 3K-Warner Turbosystems remanufacturing facility.
KKK Borg Warner Turbo Systems
Advice for fitting the Turbocharger
1. Attention! Incorrect use of a turbocharger or changes to the turbocharger
may lead to damage.
2. Therefore, we ask you to observe the engine manufacturer's repair
instructions and the following general advice.
3. In the delivery program you will find for each engine the specification
number of the turbocharger released for that specific engine. This number
must be identical with the specification number on the nameplate of
the respective turbocharger.
4. Before fitting the turbocharger, check the air and oil filter systems
of the engine, and change the filters and the oil.
5. Examine and/or clean the engine intake and exhaust manifolds. Foreign
matter in the manifolds is bound to cause damage during start up.
6. The oil feed and oil drain lines should be examined and/or cleaned
as well.
7. Fill up the oil feed hole of the turbocharger with clean engine oil,
in order to ensure perfect lubrication during start up.
8. Fit the turbocharger, using new flange gaskets. As a rule, the connecting
screws for fixing the turbine housing are heat-resistant. Use only screws
of a suitable specification. If required, you will have to correct the
position of the compressor or turbine housing in accordance with the
fitting conditions. When tightening the screws, observe the torque values
given in the repair instructions.
9. Start the engine and idle for aprox. 30 seconds before applying load.
10. After start-up, check that all air, gas, and oil line connections
are tight.
Safety Notes: Hot surfaces!
Do not touch the turbocharger during and directly after operation:
Do not hold anything into the openings during operating of the turbocharger:
fast rotating parts
Warning!
Warranty and/or liability claims against 3K-Warner Turbosystems GmbH
will not be considered if the turbocharger(s) are used without due observation
of the aforementioned installation instructions.
Additional Parts Required during Turbocharger Replacement.
Due to problems with the original heat shield and oil supply line used
with the K03 Turbo, the Audi service bulletin indicates that the following
new parts are required to maintain long life and the manufacturers warranty
when installing a new Turbo in the 1997-99 Audi A4 1.8T
Oil supply line
Heat shield
Oil line supply gasket
Oil Line drain gasket
Exhaust gasket
Exhaust Gasket to Cat Converter
For installing a new turbo, the Audi parts information also shows that
some studs/screws are required
Exhaust Bolts (qty 3)
Exhaust Studs (qty 3),
After VIN 8D-W-007800 some washers also are required (qty 3)
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