k04 set up help on my agu

[laner]

hi all just wondering if i just need the vr6 maf housing or the whole sensor ?

what ive got so far is a k04-023 with 4 pipes , both manifolds , injector rail

i no i need downpipe and a tip but is there anything else in need thanks

 

[<tuffty/>]

First off read Prawns thread as he has done the same (albeit with a hybrid K04)

You only need the VR6 housing, retain the AGU sensor... injector wise you should be looking at at least S3 ones... ME3.8's have iffy injector drivers from what I understand so not happy with some modern injectors but I would imagine early S3 (APY) ones should be ok... you will also need a K04 TIP of some description (Badger5 V2 springs to mind ;P) and a filter... what are the '4 pipes'? you will need the oil drain, oil feed and both water hoses... if you K04 comes with the EGT boss in the hotside you will need to plug that up...

<tuffty/>

 

[laner]

all that i have is from a bam engine
there is 3 pipes that come of the turbo and 1 that is tied on 1 of the other 1s
and there is a hole with 2 bolt holes
cheers

 

[Customboy]

This is my buid list so far after doing a lot of research on here and reading up hope it helps

http://www.audi-sport.net/vb/a3-s3-...6-my-k04-conversion-progress-thread-pics.html

Just got my relentless manifold sorted and soon getting a catch can, and all that's left is a decat and downpipe

 

[<tuffty/>]

Ok... should have most of the below then..

<tuffty/>

 

[laner]

cheers customboy

tuffty i have not got the pipe on the bottom right for the turbo what is it cheers

 

[Customboy]

I got a vr6 maf mate but as I bought a new maf from Audi for my stage 2 will just swap the maf elements over, many thanks to prawn for that great tip !

 

[<tuffty/>]

cheers customboy

tuffty i have not got the pipe on the bottom right for the turbo what is it cheers

Thats the oil drain... not tried a K03 oil drain on a K04 so not sure if there will be issues.. the K04 one is longer due to different position and that it has to clear the bevel box on the S3 but as yours is FWD then it 'may' be ok... assuming it will fit on the turbo itself...

<tuffty/>

 

[laner]

nice 1 tuffty

cool custom boy

cheers 4 your help

 

[Prawn]

ko3 oil drain will NOT fit on a ko4. Sorry! The fitment is the same at each end, as are the oil and water lines too, but the ko4 sits much higher up and across to one side so the oil drain won't work. That's the pipe you mention with a plate and 2 holes though, so I'm unsure which pipe it is that you don't have!

Often, you find the cooland return line has been cut, thats the one directly below the turbo in the above pic, although it's not an issue, as you can unpick the crimped joint on the cut rubber hose, and slide a length of silicon hose on there instead to fill in the gap.

Going back to your first post, you don't need the S3 fuel rail, it's no different to yours. What you do need is some injectors that'll work properly with your ECU.

For this, you're best off with old school bosch injectors. Current favourites for the AGU / KO4 setup are Saab 346cc red tops - speak to Bobby of Beach Buggy about these, they both have knowledge of them

Or if you plan to try and take things a bit further, perhaps with a full relentless manifold / dp Combo and aim as high as possible (300bhp has been cracked) then you might be better off with bosch 440 green tops for a little bit more head room.

 

[laner]

cheers prawn the bottom right 1 i have not got tuffty said thats the drain pipe im missing

injector rail comes with the injectors so are they the same as i already have ?


the coolant pipe dont look cut

im tempted to go that way (300) what i am doing is buying bits and bobs till my insurance runs out next year then shes going in the garage :icon_thumright:

 

[xs2man]

I don't think S3 injectors will fit an AGU though? Well they certainly didn't when I did my conversion. I had to go for different Bosch ones (I went overkill and went for green top 440's, but 346 red tops Prawn mentioned would have been by far better).

Having said that, I was only doing k03s on my AGU, not K04. My mate had 440's on his T3/T4 conversion running 290 BHP, and they were fine for that. So if its 300 your looking for, then 440's might well be worth a shout.

 

[laner]

so all i needed was turbo and manifold really then

 

[Customboy]

Well u might as well get the bigger manifold and downpipe mate, do it once do it right and smile all day !

 

[xs2man]

No. You will still need the bigger injectors. Its just that, in my experience, S3 injectors don't fit the AGU.

My original AGU injectors maxed out at 208 BHP, then I had to go for bigger ones (as you will obviously have to do), but my 440's were too much even when my k03s maxed out at 240 BHP. (Incidentally, my original AGU intercooler maxed out at 230 BHP too, my car was live mapped on a RR, and I had to quickly arrange these parts as their limits became apparent during tuning. If you haven't already got / considered changing out the intercooler, you might want to before you start your install. I went for upgraded twin SMIC's similar to what S3's run).

 

[laner]

I have got fmic cai 007p j vavle 3inch db cat bk
I got. My eye on some 440s that i hope to get .
I just as wellsell all i got apart from fmic its a turbo revs one

 

[Prawn]

in an ideal world, the 51mm pipes on the turbo revs FMIC are not big enough for a ko4, flow and power will be limited due to the tiny pipe size. need 60-63mm pipes on the FMIC really.

S3 injectors will physically fit with the use of USRT injector spacers (I've got some I need to flog if you want them), but for mapping the bosch 440's or 346's will work better with your ECU

 

[laner]

how much bhp will the bam injectors max out then

the pipes on the fmic is 56mm inside of pipe

 

[Prawn]

injector wise you should be looking at at least S3 ones... ME3.8's have iffy injector drivers from what I understand so not happy with some modern injectors

What you do need is some injectors that'll work properly with your ECU.

For this, you're best off with old school bosch injectors. Current favourites for the AGU / KO4 setup are Saab 346cc red tops

S3 injectors will physically fit with the use of USRT injector spacers (I've got some I need to flog if you want them), but for mapping the bosch 440's or 346's will work better with your ECU

Dude. give up on the S3 injectors!

What FMIC kit do you have with 56mm pipes? The turborevs kit is defintely 51mm OD

 

[<tuffty/>]

how much bhp will the bam injectors max out then

the pipes on the fmic is 56mm inside of pipe

around 280hp

<tuffty/>

 

[laner]

cheers tuffry just wondering

sorry its toyosports fmic my bad inside is 57mm outside is 61mm

 

[sekenzo]

No. You will still need the bigger injectors. Its just that, in my experience, S3 injectors don't fit the AGU.

My original AGU injectors maxed out at 208 BHP, then I had to go for bigger ones (as you will obviously have to do), but my 440's were too much even when my k03s maxed out at 240 BHP. (Incidentally, my original AGU intercooler maxed out at 230 BHP too, my car was live mapped on a RR, and I had to quickly arrange these parts as their limits became apparent during tuning. If you haven't already got / considered changing out the intercooler, you might want to before you start your install. I went for upgraded twin SMIC's similar to what S3's run).

Xs2man, can you explain a bit more about your twin smic setup? How does your piping work as the s3 TB is on the other side so surely it is not a straight swap of s3 oem ic piping. I currently have a larger core turborev smic and it may be a better alternative for me to fit another one to the left if the pipe work is not a pain...

 

[Prawn]

you can just lift the twin SMIC and inlet manifold setup straight off an S3 and drop it onto the A3 no trouble Sekenzo, although if you've already got an FMIC I wouldn't recommend it, as it's a huge step backwards!