The K04 install..where to begin? After having serveal people doubt the turbo, saying it will leak and just end up blowing up, I listened to the people who accuallty understand the 1.8t. And no, thats not the 1.8t forum. The plan was to start in the morning and do a straight K03 to K04 swap. Should be done by dark, not excatly.
Where all the work took place.
I got a late start that day and we didnt really start tearing into the car until after 2 that afternoon. It looks easy enough, a couple bolts here and there and it should be golden. Not really. Took off the inlet with all that good stuff, things were going fine. No major hold ups. Looks like we are going to get this done by dark, as planned.
Now getting the top oil and coolant lines isnt all that bad, expect the coolant flows everywhere without reason. Gives you a nice new scent along with a nice puddel to lay in. The cat to turbo bolts werent that bad, just the bottom one was a little tough.
Top oil and coolant off.
I lost about half my coolant. Not fun at all with this stuff everywhere.
The old k03, the thing was eating my oil like crazy. Glad to see it go, we had some good times together.
The next one was the turbo bracket, the bracket from hell. It was a bracket that bolts to the side of the turbo then wraps around under the turbo and attactes to the block. I believe it was a 6mm hex, 10 grade or whatever they call them. Meaning you have to crank on them until you break it loose, or strip the bolt into the a round piece of metal. We had the 2nd option chosen for us. After stracting our heads for a good time and trying various things like trying to pound a socket on it wasnt working. So we just say screw it bust out the dremmel tool and decide to cut it off. Well, the dremmel head breaks off and delays us big time. Under the turbo is the oil return line, blocked by the damn bracket. The bracket had to go.
Finally got the damn bracket out and finished getting the oil return line out. By that time darkness set in.
Time came to put the new turbo in. The oil return line under the turbo is the hardest part because 1. you cant see anything. 2. your under the car on your back. 3. your fighting gravity. Everything else is pretty much in reverse order. It wouldnt of been bad at all expect we couldnt see anything. But we managed to do with a flashlight and a little light from the laptop.
The rest of the stuff went back tonight nice, except the turbo inlet pipe. We couldnt get it to clamp right on the turbo. I think we were just tired and wanted to get done. So with everything else ghetto rigged up the car was ready to go. Started it up, no cel. Everything sounded good. No coolant light either, I was surprised by that. So thats it, right? Hur-ray!...Not really.
There was still the issue of me getting home, a good 40 mins away. And thats at 80 mph the whole way. So first the issue was going to get disstilled water to add to the coolant. Giant Eagle was open, so I headed over that way. Then I took off slow, didnt feel any different. I knew my intake cone was off because the sucking sound was way too loud. Went about 10 mph the whole way and parked it.
Went in and got my water. Went to check out and the cashier took one look at me and said ''Working on a car ..eh?'' I smiled. I dont think I said anything, I was too tired to move my lips open. Went outside and filled it up. So the coolant was good. Now I needed gas. Ran down the road to the gas station. Its packed. 2 in the morning and the gas station is packed. Theres a line a mile deep inside and every drunk from the bars is there getting a cold cut sandwich paying with crumbled dollar bills and loose change that they didnt tip the bartender with. Finally got out of that mess and made my way onto the turnpike. Didnt boost at all the whole way home. I maybe saw 3psi at one point in time. Everything ran really well.
I was starting to see the light.
Sooner or later I made it into town without any problems at all.
Now, with home in sight, It was time for a full out run up and down the road a few times. It was past 3 am so everything was good as far as other cars, police, ect.
Now, I pull out first gear and at first when you hit boost it feels like a regural chipped K03. But once you get close to 4000 rpm, it steps it up to another level and the car takes off. The front end lifts and its just another level than Ive ever seen on my K03. Second and third gear was kind of a let down, wasnt the same kind of experience that it was in 1st gear. But it still felt strong. Didnt get a chance to really test 4th and 5th because I'm over 80 when running out 1st through 3rd. I went home, let the car cool down for a good while, shut it off and went to bed.
Couple things I noticed about the install.
1. If you reallllly dont know your car or how it works. Dont try to do this by yourself. It may look like a straight swap, but its not as easy as it sounds. Not by a long shot.
2. You need another person to help you, I have no doubt in my mind that a single person cant do this job by theirself. Its just not possible. Too much stuff needs to be held in place and its just not going to happen if your flying solo on the job.
3. Make sure you have probably 50 bucks in your pocket ready to be spent. Because your going to need the money to go by random stuff like tools or a few odds and ends.
4. Plan ahead! If your going to do this, start about 8 a.m. or earlier. You'll save yourself from working in the dark later. I made the mistake of starting too late and it hurt me in the end.
Last but not least. Thanks to Mark and Val for helping me on the job. Especially Mark. I would of been up **** creek without them. So, in the end. Is it worth the upgrade? Yes, especially if your going to be using special fueling, fmic, 5 bar, all the good stuff. With all the bolt ones, you should have a solid 280 ft lb.