75 replies to this topic

[Alex-B]

hey guys been on here a while hiding away and looking at things but i allways end up just a bit more confused when i start reading and not having the car to see what people are talking about so im going to attempt this way and hopefully some of you guys can help me along the way

i have some mechanical knowledge but i have never touched a car with a turbo i understand the priciples of how they work but after that im lost haha i have no idea on sensors ect ect

basically my octy is currently sat in the unit with the front end stripped down to be able to look so the first question of which i cant find the answer

does the engine need to some out or can i acess the turbo from underneath if i strip the subframe off?

im aiming to achieve at the end of all this a stage 2 map on a k04 with a fmic and atmospheric dump its allready got a decat system on it and some bigger injectors i also think ill need an audi S3 maf from a few things ive read

im gunna almost treat this as a build thread and if i stumble across any issues this way i can have pictures ect and also hopefully then it can possibly be used to make a bit of a guide at the end for others wanting to do this

heres the car btw just in case anyone wonders haha going to fit the fmic (hopefully get one made to fit exactly) to fill the centre vent of the bumper including where the no plate sits

[IulianE]

I just like the wheels...

[jonesy_04]

I have no idea other mate. But your car looks nice and cant wait to see it when its finished.

[Alex-B]

thankyou guys
im acutally doing a couple of other things whilst its off the road (sorned it last night driving a *sigh* saxo :/ currently haha)
getting the chassis notched and getting it sat a little lower

main one though is the engine build

[RobClubley]

Sounds like a good project. Turbo and manifold are at the back of the engine but should be changeable without needing the engine out.

[Alex-B]

i did think it may be possible from underneath to do with engine in but wasnt sure

[cntuning]

You will have to change exhaust dp anyway if going k04-022

You can get to tubby from under with no issues

Are you going to put some Rods in to be safe ??

[Alex-B]

didnt know the downpipe was different is there.not one the same my dp is like 6weeks old
and rods really i thought the internal would take a k04 easy as the bam has them thats the same bottom end isnt it?

[Oet]

no the bam and other 225 variants of the 1.8t run uprated internals unlike the 180 auq.

why not consider a ko3 hybrid, running ko4 internals, that way you can avoid having to change you dp (though fitting a better turbo intake pipe and down pipe along with sports/decat would be advantageous in creating a nice setup)

[Alex-B]

i didnt know they.were different internally i.just knew the heads were

k03 hybrid i assuming is a k04 in a k03 housing as such?

ive got a miltec downpipe on atm and the intake setup will be changed anyway as thats where the dump recirc goes so id swap that out when i put the atmospheric on

[Oet]

yes they are different, depending on the power you are looking for i would say you could get away with the stock internals, depends on how you se the engine too i guess.

ko3s hybrid is a modded ko3s, however you can get them basically with ko4 internals so in effect they are like a ko4 but without the effort of changing to a ko4 setup.

thats what i would do.

[RS Mac]

Stick with the re-circ dump valve, just get it uprated!

[Alex-B]

see this is exactly why ive made this thread
thankyou for that info fella im looking for anywere over 260/270ish hopefully

a k03s hybrid should fit straight in then no real messing??

im going to be getting an intercooler made to suit so the boost pipes should be ny only real issue then??

[Alex-B]

RS Mac, on 08 August 2012 - 10:12, said:

Stick with the re-circ dump valve, just get it uprated!

i want a chavvy little tishh on shifts lol

[steve954]

If I'm not mistaken  260 bhp can be achieved by using a k04-001 ! And I've been told these can be bought from tps for around £550.

[RickVRS]

you get that anyway with a recirc if you have the right set up.  mine is loud on an induction kit!

as for the turbo ive changed mine unbolting from the top and bottom.  quite easy.

[Alex-B]

steve i dont know variants ect i.just knew k04 was the bigger version
id love to see more but i would worry over 290 about internals on any engine ive seen cars with 280ish so somwere near and aim low to not be dissapointed on the mapping session haha did that with my.106 wanted 175hp ended up at near 190

and rick thanks for confirming i can get in there

[steve954]

Well what I am doing is putting on a k04-001 which is a direct bolt on! I have just bought a bam inlet manifold to help with the fmic side of things, my biggest aim is to get everything flowing the best it possibly can which will mean moving things about and fabricating pipes as I go.
Hopefully I should see a safe 250bhp with the work I'm now about to do.

[Alex-B]

oooh interesting stuff
im going to run a custom fmic to keep the inlet mani side rather than swap about

[skud vrs]

looks like there is a few of us after more power.

Has anyone on here tried and tested the k04-001.
How would it compare to the k03 hybrid...

I am also looking at a turbo upgrade, wanted figures around 260 - 280bhp hopefully still keeping engine reliable.

[Alex-B]

few of us looking for the same thing then

im after one as my k03 has failed on the nurburgring lol if im changing it i might aswell put a bigger one on

[Chronicbint]

Can I have your address? Also if you can leave your locking wheel nut key handy. Cheers.

[Alex-B]

im brave and dont have locking nuts
cars in a locked alarmed garage though so unlucky lol

mind its sat on beetle steels atm anyway as the bbs im thinking need to be a different colour

[Bowders1]

steve954, on 08 August 2012 - 11:40, said:

If I'm not mistaken  260 bhp can be achieved by using a k04-001 ! And I've been told these can be bought from tps for around £550.

This is a good thread as there are a few folks wanting better power from the std small K03s.

There are various routes to go but as CNTUNING states the BAM engine was designed to take more power from the go with better internals and fuelling,air/mapping to support it. This is why a few folks don't go all out for a BAM engine replacement turbo K04 as injectors, manifolds,MAF etc will all need replacing and also if you want over true 280 defo internal mods will be needed.

This is why a K03s Hybrid or even a K04-001 could be options as you can retain your manifold and needs less parts replacement.

I am going this approach as well although my 142,000 miles makes me think don't as been very reliable up till now. But the engine is strong and losses no oil so what the hell ( As CNTUNING Clive can report after just mapping to stage 2 shark) my power is already very good but now the K03s is at limit and running out of puff.

perhaps we could do a group buy based on best recomendations????

for me a true 260-270 is enough.........................for now

[Alex-B]

quite interested in the 001 is it this one that id need??

http://item.mobilewe...nid=37479044694

got my intercooler core last night i think
not quite what i wanted but hugely cheap so **** it
should flow 300hp so 260/270 wont be a problem and it should look fairly large in peoples mirrors haha

Edited by Alex-B, 09 August 2012 - 09:17.

[steve954]

Well my mind is made Up I'm going the k04-001 route and I have started a new progress thread in the project section.

[Duncan Grier]

I converted a k03s DBW 20v turbo lump in my renault 5 turbo to ko4 and ran about 290bhp for 20k miles without any blips and about 30 track days (and 100 odd laps round the ring)

TBH 20VT is old tech now and better upgrade would be a cheap tfsi out of the golf gti. Been higher compression and direct fuel injection etc etc would be a better bet imo. I am using the k04 variety tfsi in the vx220 conversions and that makes a nice easy 375bhp with uprated head pump and software

I was tempted to drop this engine in my skoda 4x4 estate but alas company car has resulted in it now on ebay for a steal for someone as I only just finished a strip down / rebuild / upgrade of just about everything :(

Wheels would look great on a silver 4x4 estate

DG

[Alex-B]

hadnt considered a totay different motor tbh and i dont think id wanna go that route as surely the looms ect differ
im only doing this as my tubby failed and if im ****ing about id.rather end up with something to show for it

[Duncan Grier]

Fair point, just with these engine going for approx £500 with software is about the same power as the 1.8t on k04 its a lower miles engine cheap. Bolts to current box and only the engine side mount required.

Depends on your garage tools / and confidence as it could get expensive paying everyone

Sure you will notice the gains with the route your going

Enjoy
DG

[Bowders1]

Duncan Grier, on 09 August 2012 - 13:33, said:

Fair point, just with these engine going for approx £500 with software is about the same power as the 1.8t on k04 its a lower miles engine cheap. Bolts to current box and only the engine side mount required.

Depends on your garage tools / and confidence as it could get expensive paying everyone

Sure you will notice the gains with the route your going

Enjoy
DG

That interesting actually as thought the newer engine would be much more expensive. Can see why this would be a option. The costs would be approx equal across both routes but that depends on who is doing the job as you state.
For now I am going replacement turbo route , but if engine dies then TFSI here we come I think

I remember swapping out my Pug 309 Goodwood Gti from a 8v motor to a Mi16v motor and that was reasonably easy apart from ECU and loom wiring..