Hi Guys

I'm Starting my S3/Leon Cupra conversion and was wondering if you could add any info and parts you think I'm missing.

I have the following items:

-Leon Cupra K04 Turbo with Manifold and WG (same as S3)

-Leon Cupra Injectors (same as S3)

-Leon Cupra DV relocation kit

-Audi S3 Intercooler and HPFP

-Forge Boost pipes

-All needed gaskets for the fitting

Turbo came off a 1000 Km Leon Cupra that upgraded to stage 3 APR.

I will also be taking the Leon Cupra Brakes and fitting them on my car.

Can anyone tell me if I have all the parts and if there is anything missing?

Also do you think original rods will hold in this setup or should I upgrade the rods as well?

Thanks.

Edited 28 February, 201016 yr by Petelking

-Audi S3 Intercooler and HPFP

The Audi S3 HPFP is the same as the one fitted to your VRS - if you want to get the maximum benefit you'll need one of the uprated ones available e.g. APR, Autotech etc etc.

Check out JKM's K04 conversion page, it lists what you need fairly conclusively.

Don't forget you'll need a new remap on top as well - good luck with the conversion!

Thanks for your replay

Regarding the Audi S3 pump, I'm quite sure it's better then what I currently have as the fuel pumps that came in the early 2007 models has a different part number then the later models and S3's

.

I am, however, aware that I won't be able to get the maximum out of this conversion without an APR or Autotech fuel pump conversion but then again I am not likely to push this turbo to the limit without new rods and pins.

I also use WM injection to compensate for the fuel pressure issue so it should be fine initially, I will later upgrade the fuel pump and with the WM kit, I am planning to do the most aggressive tune possible, and I always do a custom tune but that is only because we do not yet have a Unitronic representative here in Israel.

Thanks a lot anyway.

Shark Performance may be able to help you with there STS Unit.

300-330bhp shold be fine on stock internals, after that you'd be better rebuilding up uprated crank rods and pistons. People have gone well past 400bhp on stock internals but i think thats just asking for trouble

Thanks for the tip

I am more worried about the K04 and engine internals then I would have been with a big turbo.

The K04 gives a lot of torque in low revs and I know that’s where the rods stress the most.

Regarding pistons, I was supposed to get them of the Leon cupra I'm taking the turbo from but the guy decided to keep them after all.

I wasn’t aware of any piston issues with this engine, do you know of any? I only wanted the pistons to lower the compression ratio but except that did not see any problem with stock pistons.

About the tune, I am very happy with my local tuner here in Israel, they are very creative and always keep in mind that the car needs to be reliable and daily.

Edited 1 March, 201016 yr by Petelking

You will be fine running stock internals with a K04 turbo.

I'm running 348bhp 400lbft on stock internals and it's perfectly fine.

You will need an S3 front intercooler pipe for the DV relocate, as well as a new discharge pipe on the turbo outlet.

Apart from that your list is fairly conservative and you should be good to go. I would highly recommend revo stage 3 software also.

I would also suggest a full set of VF Engineering engine mounts and perhaps an LSD if your budget will stretch - getting the power down is a lot more difficult at this level. HTH

That’s an awesome tip, thanks!

I already have larger forge boost pipes and I also have the original S3 pipes in case the forge ones don't fit on the K04, LSD is the next step but I haven’t given any thought to engine mounts so I'm very happy you mentioned this to me.

What about the clutch? will the stock clutch hold?

I really like the dual mass clutches as I drive the car on a daily basis and the noises and vibration from a single mass clutch is something I would like to avoid.

I know sachs make a dual mass clutch that should be good with up to 400 BHP, does anyone have any experience with it?

Thanks.

I am still using the original clutch on my car - no problems yet I tend to drive sympathetically though, I don't hoof it when the revs are low I will always pop it down a few cogs to get the revs up.

The Forge boost pipes should fit fine I think, 95% sure on that.

Oh, and one more thing. Get a loan for some fuel because after doing the conversion all you'll want to do is drive!!!

Thanks for your replay

Regarding the Audi S3 pump, I'm quite sure it's better then what I currently have as the fuel pumps that came in the early 2007 models has a different part number then the later models and S3's

.

I am, however, aware that I won't be able to get the maximum out of this conversion without an APR or Autotech fuel pump conversion but then again I am not likely to push this turbo to the limit without new rods and pins.

I also use WM injection to compensate for the fuel pressure issue so it should be fine initially, I will later upgrade the fuel pump and with the WM kit, I am planning to do the most aggressive tune possible, and I always do a custom tune but that is only because we do not yet have a Unitronic representative here in Israel.

Thanks a lot anyway.

I would personally say upgrade the HPFP, I do know an S3 owner, quite familiar with this forum actually who did just that.........!

Infortunately even given the revised fuel pump part numbers the configuration of the TFSI cam/fuel pump outlay does lead to a weakness in that area after mods....Good luck.

Just came back from a few log runs.

got the "Fuel Rail/System Pressure: Too Low" fault so I guess an Autotech HPFP will happen sooner than I thought.

Have you had your kit fitted already??

Oh, and one more thing. Get a loan for some fuel because after doing the conversion all you'll want to do is drive!!!

Can you try to keep the miles down please Harry, I'd like it all in as new condition as possible when you sell it to me. Thanks.

O.K

After some digging about HPFP's I realized that the only real safe option is APR, lucky for me the ARP shop is a five minute walk from my house so a quick stroll and some friendly talk scored me a brand new APR HPFP.

I did not install it yet as my car is still tuned with the S3 pump and I don't want to spend time tuning the K03 when the K04 project is starting in less than a week.

Thank you all for all your help.

I will start a build thread as soon as I start the project.

Cheers.

In theory the tuning shouldn't make a difference - until you get a different map on the car that actually requests more fuel, the APR pump will behave the same as your standard S3 pump.

I would agree with you on the APR HPFP. It's the only one to buy now IMO - I have an autotech pump and it has seized twice since fitting it (all been fine for a long time now though)