My K04 A3 2.0T build Thread

[hatmeow]

Guys,

I have been in this forum for over a year and I think its the best Audi Forum yet! My car is approaching what I consider as "Perfect" status and I would like to share its story with you.

It started out 2 years ago in 2007 May when I got my A3. I didnt want to do anything to it as it was already an expensive car for me. All the changes it had was 18in RS4 reps. One thing led to another....

Then I started... first with an MTM stage I remap... Then I found out that the brakes weren't good enough for 250bhp. so I went for this...Brembo 6 pot from a Cayenne and 345mm slotted disks

Then I didnt like the really bland looking non S line front end so I added an OSIR front lip and an Oettinger Rear wing (and a S line badge which I later removed).

Well of course for more power I added an Oettinger Ram air intake and the Oettinger Turbo Outlet pipe. I really like the combo as the top end has improved without sacrificing low end.

Several months later I was bored of the car again and needed more power (I am falling into a black hole) and the means to tame that power. I just had to upgrade the suspension and exhaust. I chose PSS10 and Miltek TBE. I am still in love with the Miltek because its so quiet and stealth!!

I also changed my Chip from the MTM to Revo stage II because MTM does not offer the stage II alone and Revo is so much better with the Select Plus!! Power is expected to be in the area of 270bhp now.

Of course thanks to the Devils in this forum the stock non s line look just did not cut it and I HAD to go with the S3 front bumper and grill and the S3 mirror covers! I also installed HID and Lens. This is crazy but I am loving it!

Next of course came the 09 Facelifted rear LED lights!

I also fitted Carbon Textured interior and exterior trim peices.

This is what it looks like before the K04 Install with shaved badges.

Contintued in Part II!!

 

[hatmeow]

Continued from Part I

My car remained in this state for over 6 months without major changes except for a Vent Boost gauge and a FBMFSW from NSN.

It has been my dream to blow a Porsche or two away with this car and I know this can only happen with a K04 (well later I found out not all Porsches) .

This is the Box of goodies that I have been waiting for WEEKS for

This kit was purchased from Revo which included K04 with all the S3 pipes and fittings, S3 injectors, and uprated pump internals. Of course this kit uses the Revo K04 map that puts out approximately 320hp.

The Turbo before installation.

This is what it looks like when the 2 turbos are compared

Notice that the size of the turbine is bigger on the K04 without a flange.

This is what it looks like when the turbo is removed.

And the new one installed.

I also bought a S3 intercooler while I was at it

Note that the ends are in alloy rather than the cheap plastic of the regular 2.0T

During the installation. I can hardly recognize my car

The whole exercise took over 3 weeks as my shop really took their time... Quite a frustrating wait. But this is the result together with a new set of OZ Palladios, Bridge stone RE001 and 09 S3 SB sideskirts. Its all worth it afterall!

I have also added TT front arms for more camber adjustments.

My next plan is to add the 09 S3 rear bumper with the diffuser and the exterior will be complete. I also plan to finally go for a CAI and a DSG Remap.

Please feel free to comment! Good or Bad comments always welcome!!

 

[emzino]

Wow. An amazing story with amazing results. Must have cost so much which leads me to my next question, why not just get the S3 SB?

 

[Staz]

Not sure why you chose to split this into 2 parts mate but I've joined them together now. It just fragments the board and uses up unnecessary space!

Great thread how much power are you expecting total?

 

[Dandle]

Great work is it a FWD car as I cant make out prop or rear driveshafts(not sure if im missing them).

Wow. An amazing story with amazing results. Must have cost so much which leads me to my next question, why not just get the S3 SB?

Thats my thought too. S3 engine is a stronger engine than the 2.0T and comes with all the S bits so would be a better starting point.

 

[kaz219]

Love it mate - bet that must go like stink and you'll defo be eating porsches with that.

Looks really good as well - the S3 rear will finish the looks of nicely IMO.

Well done mate - liking it a lot

***Editted to make sense now lol

 

[Young un]

Quite like the OZ Palladios on your motor. You've caught the modding bug!
By the way, you based in HK? Looking at the latter pictures, I can see street signs with both english and what appears to be chinese symbols

 

[emzino]

HK?! Right Hand drive in HK?! Wow didn't know that

 

[hatmeow]

Wow. An amazing story with amazing results. Must have cost so much which leads me to my next question, why not just get the S3 SB?

Well I have spent nearly enough on my baby for an S3 but It all started doing things bit by bit so it did not seem like a lot at first! However, I think just getting a stock S3 will not nearly have as much power, handling, and Braking as my A3 right now. The only thing I lack is actually the Quattro which I miss a lot!

Not sure why you chose to split this into 2 parts mate but I've joined them together now. It just fragments the board and uses up unnecessary space!

Great thread how much power are you expecting total?

Thanks Staz for linking them together!!I didnt want such a long thread at first so I broke it in two. I think its much better now. Thanks again!! I have not put my car on the RR yet but I am expecting about 300-320hp.

Quite like the OZ Palladios on your motor. You've caught the modding bug!
By the way, you based in HK? Looking at the latter pictures, I can see street signs with both english and what appears to be chinese symbols

Yes Yung **** I am from HK and the cars here are in RHD just like in UK. From what I know my A3 is the fastest A3 out here for now... A friend of mine is setting up her A3 with a GT3071 turbo!!! She is looking into 400hp!! Crazy!!

 

[S3 Rav]

great thread.

 

[S.]

nice work hatemeow
where did you get those carbon b-pillar parts or it is a carbon film?

 

[Boydie]

Great build thread however, I think you need to go a bit lower to pull the whole look/feel off!

 

[hatmeow]

nice work hatemeow
where did you get those carbon b-pillar parts or it is a carbon film?

Read all about it on this thread...
http://www.audi-sport.net/vb/showthread.php?t=63134&highlight=carbon

This stuff is amazing but might not be available in the UK. OSIR also makes interior and B-pillar carbon inserts as well. Super high quality but does not come cheap http://www.osirdesign.com

Great build thread however, I think you need to go a bit lower to pull the whole look/feel off!

I have actually tried another 10mm lower before and it just looks sooooo much better. However, I changed it to the current height because this set up actually lets me have a bit more suspension travel for the sometimes rough roads here.

Focus RS anyone? J/K Nice work!

I though about that too and constantly compare the 2... 300hp FWD + a great chassis... Now all I need is a Quaife LSD and my Ford...er...sorry Audi is complete!

great thread.

Thanks! Glad you like it!

Just wanted to add that I totally recommend the change to the TT front suspension arms as now with -1.5deg camber the handling is nothing short of AMAZING! ESP seldom comes on and the front just STICKS to the tarmac. All the benefits of a good mod while also enjoying OEM quality. Details here. http://www.audi-sport.net/vb/showthread.php?t=71940

 

[~RS~]

That's some TLC gone into that! And a s**t load of cash
Nice car mate, I am not decided on the rims yet although they look good, not sure I'd rock them. What I will say about them is the look very OEM, very much like the type of rim Audi likes putting on their cars at the minute.

Look forward to the reports of disgruntled Porsche drivers How about a nice 35% tint all round?

 

[10blazin]

how much was it for the engine mods ??

 

[hatmeow]

That's some TLC gone into that! And a s**t load of cash
Nice car mate, I am not decided on the rims yet although they look good, not sure I'd rock them. What I will say about them is the look very OEM, very much like the type of rim Audi likes putting on their cars at the minute.

Look forward to the reports of disgruntled Porsche drivers How about a nice 35% tint all round?

how much was it for the engine mods ??

Yes its a S**t load of cash but I am still JUST under the cost of an S3. I figured (also to justify this spending) that if I get an S3 I still have to do the things I did (suspension, brakes, exhaust, Intake, remap, except for the TT arms and the K04 kit) to get to where I want the car. Also the S3 SB was not available 2 years ago and I have a family to haul around. I guess anyone will have their perfect excuse for blowing this cash into a car.

For me I am keeping this at least for another 4-5 years. Its time to enjoy it!!

Personally I am all for the OEM+ look rather than a tuned look so I am happy without the tints and the OEM look of the wheels. My only gripe is that the OZ wheels are on the heavy side (25.5lbs) and are looking into getting lighter ones later. These are some of my chloices...

Enkei SC05 - (18x8@17lbs, cast)

Or this: Yokohama Advan, Kureutzer xi (18x8@16.5lbs, supposedly the lightest cast wheel on this planet)

 

[S.]

wow, those enkei are nice, and light.

 

[phille87]

Mate, did you have to change anything else when you changed the turbo??


I mean, fuel pump, or something else??

 

[hatmeow]

As mentioned in the original post, I have changed the pump internals to a higher flow one. Aside from that I have also added S3 injectors and an S3 intercooler.

An APR complete fuel pump is on order so I will post up a review and compare the 2 afterwards...I suspect that there will be no difference except for durability and reliability

 

[~RS~]

Hi mate, no justification needed on the spend.... t'is your cash and you call it how you see it. I think you've done well if your car will beat S3's, looks great and all for less than an S3.

I like the regality of the yoko's badge, looks a bit like a set of khans my friend has on a brabus S-class... The fact they are also 'supposedly' the lightest wheel on the planet (has a great ring to it that !) would also make me get them... bragging rights n' all Few less pounds will help beating them porkies too!

 

[hatmeow]

Hi mate, no justification needed on the spend.... t'is your cash and you call it how you see it. I think you've done well if your car will beat S3's, looks great and all for less than an S3.

I like the regality of the yoko's badge, looks a bit like a set of khans my friend has on a brabus S-class... The fact they are also 'supposedly' the lightest wheel on the planet (has a great ring to it that !) would also make me get them... bragging rights n' all Few less pounds will help beating them porkies too!

Well, I just had to say something to make myself feel better as it's really a SH** load of cash

The yokos are actually the lightest cast wheels available but forged ones can go a bit lighter (short of going for dymags) these cast Yokos go for about 400euros here so it's a cheaper way for lighter wheels than the forged ones.

 

[drew138]

Simply Awesome. I'm considering something similar for myself here in the US where the S3SB isn't even an option.

Is there any chance that you have a complete parts list for the upgrade to the engine?

Congrat's and thanks for the build thread!!!!

 

[hatmeow]

Drew, for the engine upgrade just go to APR, AWE, or KMD and choose the cheapest K04 kit. All have the same / similar VAG parts in the kit so there is little difference. 100% OEM reliability and fit and finish. APR and AWE use Giac software and KMD uses Revo. Both good and reliable choices.

APR
http://www.goapr.com/products/turbo_trans20t_k04.html

KMD (should be the cheapest)
http://www.kmdtuning.com/index.php?_a=viewProd&productId=1109

AWE (most expensive)
http://www.awe-tuning.com/pages/sha...0t_drivetrain.cfm&PPT=Drivetrain&IL=mk5k05kit


I would suggest to go with the kit with the injectors (usually S3) and the upgraded pump internals. If you are living in hot places, you might even consider the S3 intercooler (cheapest way out) or the Forge Twintercooler (Expensive but Best Setup IMO) for more consistent HP.

Just one suggestion. Get your brakes done first!! You will need a minimum of a 4 pot front brake system (brembo, Alcon, AP etc) to stop this monster after the engine upgrade. A R32 brake upgrade just wont cut it anymore.

 

[drew138]

Thanks. Loving your work here! A true inspiration!!!!

 

[hatmeow]

Update:

Just wanted to share this experience of another mod that I did this past week. Its another one of those "I cant believe its that simple" mod that is good value for money.

The part in question is the Eurojet throttle pipe. Its the tube that comes out from your intercooler and into the throttle body of the 2.0T engine. (the biggest diagonal black plastic tube in front in the pic below)

The original tube is a short and flattened plastic tube that does not look very appetizing. Replacing this is a much thicker, longer stainless steel pipe that with good welding quality.

Installation is not easy as the pipe is much bigger that the original part. It takes a bit of time to fit this part as the space is very limited in that part of the engine bay between the radiator and the engine but it all fits perfectly at the end.

The feeling of this part alone is very satisfying. It feels like opening up a nose blockage that you did not know you had. I really wondered why VW /Audi did not change this in the first place as this is only a small part that makes such a big difference.

The throttle response is much improved in the whole rev range especially during low revs. Turbo lag is reduced and you can feel the engine breathe much more freely than before while being more linear. The engine feels much more responsive and the rev speed feels much quicker. Neuspeed also makes a similar product and I would expect the results to be very similar.

Big, thick and long is always better than Small, Flat and short!!

 

[mnoble]

impressive list of mods, how is the DSG box holding out?

are you still on the original stock gearbox/clutches?

 

[WiZBiT]

Nice write up and a very nice car

I miss HK soooo much

 

[hatmeow]

impressive list of mods, how is the DSG box holding out?

are you still on the original stock gearbox/clutches?

Yes, I am still on the original box and its holding out perfectly. frequent oil changes to the DSG is a MUST!! No less than 20,000kms between intervals.

My next mod to the box will be a DSG reflash. Will update this thread once its done!

Nice write up and a very nice car

I miss HK soooo much

Pollution, noise, and great food... I guess you miss the food?

 

[phil76]

Update:

Just wanted to share this experience of another mod that I did this past week. Its another one of those "I cant believe its that simple" mod that is good value for money.

The part in question is the Eurojet throttle pipe. Its the tube that comes out from your intercooler and into the throttle body of the 2.0T engine. (the biggest diagonal black plastic tube in front in the pic below)

The original tube is a short and flattened plastic tube that does not look very appetizing. Replacing this is a much thicker, longer stainless steel pipe that with good welding quality.

Installation is not easy as the pipe is much bigger that the original part. It takes a bit of time to fit this part as the space is very limited in that part of the engine bay between the radiator and the engine but it all fits perfectly at the end.

The feeling of this part alone is very satisfying. It feels like opening up a nose blockage that you did not know you had. I really wondered why VW /Audi did not change this in the first place as this is only a small part that makes such a big difference.

The throttle response is much improved in the whole rev range especially during low revs. Turbo lag is reduced and you can feel the engine breathe much more freely than before while being more linear. The engine feels much more responsive and the rev speed feels much quicker. Neuspeed also makes a similar product and I would expect the results to be very similar.

Big, thick and long is always better than Small, Flat and short!!

How do mate nice thread and interesting to me because i have the same motor and was thinking about doing this conversion if or when the cash comes around,how much was this pipe you purchased matey

 

[hatmeow]

Check it out here http://www.eurojetracing.com I paid about the equivalent of $170 Euros here without installation. Note that there is no need to remove the radiator and bumper but it takes a while to maneuver that big pipe in that small space (we played around for over 2 hours). Fit is very close to being perfect.

 

[heyadamhey]

Big, thick and long is always better than Small, Flat and short!!

baaaaaaaahahahahah

sorry, couldn't resist

Nice write-up mate.

 

[The Cardinal]

This car is a real inspiration. I really love the "OEM plus" look; it's exactly what I try to achieve when I do modify my cars.

I've got the same starting point as you, in that I'm soon to collect a Garnet Red S-Line 2.0T Quattro Sportback. If and when I do modify it, I will be visiting this thread again for the details!

 

[hatmeow]

Hi guys,

Its been a long time since I updated this thread as I am working in another city without moving my car over and she has been neglected for a long time...

Latest Update: Since my K04 install on My A3 2.0T I have always been with Revo for my map. I have installed an analog boost gauge and found that my Boost goes over 2 bars every time. Thinking that I have a faulty guage, I ignored it and drove it for a couple of months until I changed to a Defi Digital Guage and found out that my car was maxxing out at over 2 bars. I immediately went for a VAGCOM log in my local garage and the map was making 2.6 bars of boost from my poor K04. This was CRAZY!! . This garage also tested my car and found that the low end was no where near as strong as the K04 should be. There was definitely something wrong with the Revo Map. Using the Select plus I turned down the boost from 7 to 3. The car was still making about 1.8-1.9 bars and peaking over 2.0 bars but the low end is quite soft.

I then decided to switch to Unitronic, a Canadian chip tuner who has had good reviews locally. Now the car is perfect with a steady 1.6bar peaking at about 1.8bar. Most importantly, the car has much more low end torque than before and it revs much more smoother. Power is more linear and much more satisfying in the city.

I would think that my Revo experience might be an isolated case as there are so many good reviews. But I think that Unitronic is a very good alternative as its the most linear chip I have tried (MTM, REVO, Unitronic). Not sure if there is a dealer in UK though.

Happy Modding!

 

[Scott134]

Hi. I hadn't seen this thread before. Very interesting read and some great work you've done on the car there. Just out of interest, did you ever get it on the rolling road to find out what power it was making?

 

[akash_sky1]

Unless I get a new car/or a bike next year Im going down this route for a laff

 

[hatmeow]

Hi. I hadn't seen this thread before. Very interesting read and some great work you've done on the car there. Just out of interest, did you ever get it on the rolling road to find out what power it was making?

Its not been on the rolling road but my friend's GTI has the exact same set up except for a 1/4inch narrower exhaust. He made 330hp on the rolling road so I would expect that my A3 would have about 310hp - 320hp.

 

[hatmeow]

Its been a while since i have updated this thread but the modding is still going on. Some further changes to the car.

APR fuel pump - The KMD pump died and its time for the best pump there is. The APR pump is simply amazing as the low end torque actually improved! The result is a much smoother low end and the engine feels like it its has a slightly bigger displacement! Super investment and an unexpected surprise.

Snow Performance Methanol injection - This is a very very good investment. There is a tremendous rush of torque when the meth kicks in and feels much much stronger. It easily pulls to the red line and feels very eager, never out of breath. The push is even felt at high rpms in high gears. I dont know who invented this mod but it sure works!

 

[N.Singh]

Looks Good Bud