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A3 Quattro KO4 upgrade, its started

Discussion in 'A3/S3 Forum (8L Chassis)' started by phil miller, Sep 17, 2012.

  1. phil miller
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    phil miller Member

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    [Sep 17, 2012]
    Hi all, right after hi jacking Coatesy build thread i thought i should start mine, that way i can put all the info in here

    Now the car is a 2001 Y plate A3 Quattro, 90,000 miles, 5 dr in burgundy, the inside is a horrible beige colour, now i bet your all thinking why buy it, well here is the answer, it was so cheap id have been a fool to say no, basicly it belonged to a customer of the garage where i work, he had always had loads of work done, new lambda sensors, DMF and clutch, coil packs, whatever it has needed when its needed, BUT the one thing it hadnt had was a service for 13,000miles (yep you got it, 20k service was his route) so one monday get to work and the quattro is there, he left a note saying he was on the motorway, the oil light came on and it cut out
    So after removing the sump to check the pick up and finding it full of **** the ARY was dead, we priced up a replacement engine and the customer said he would scrap it, he was almost in tears so i offered him a little more than scrap money (you prob have an idea how much i gave for it lol) my plan was to replace the engine, put 12 months MOT on it and flog it on up the line, so i found an AGU (150 not 180 like the ARY) very very cheap, knew the owner so took his hand off, now the AGU came without a turbo, this has proved to be the turning point in this car

    I had some time off and thanks to cornwall being under water came home sooner than planned, took the time to take the ARY out of the A3, i swapped over everything, i only used the AGU head and block, the ARY gave its rocker cover, inlet and exhaust manifolds, wiring loom and pipes, first problem found, the AGU doesnt have EGR so the sensor is plugged in but unable to do anything, second problem VVT unit on the ARY was melted, so to prevent poss limp mode i just connected up the sensor so all back together and running well i took her for a road test, christ she went well, not holding boost overly well but TBH the turbo must have been cooked, anyway used it for a few days and checked the oil, at this point the turbo issue was a massive one, it had drunk over 1 lt in barely 120miles, time to think, replace with a KO3s and sell or due to the amount the car owed me go mad keep it, but me being me would prob get bored in no time so after chatting with Russ who has an S3 i decided to go down the KO4 route and aim for 260 BHP, the list was drawn up, i found a KO4 exhaust manifold and down pipe, and a turbo, its meant to be in very good nick, when it arrives if it isnt then i will get it rebuilt or hybrid'd, gotta get some BAM injectors (im using the ARY TB thats DBW) a FMIC a TT MAF body i think thats all for the mo (please add if ive missed anything)

    Russ has a TIP for me and fingers crossed some 312mm carriers to help stop the thing, here are some pics of her, not the best but hey ho, more will follow lol

    any advice is more than welcome
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
    #1
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  3. phil miller
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    phil miller Member

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    [Sep 18, 2012]
    here are some pics of the dead ARY head that i had to remove
    you can see the cam jurnal has picked up in the head
    [​IMG]
    the head had melted it got that hot
    [​IMG]
    and this is the chain end of the inlet cam it has picked up quite bad on them
    [​IMG]
    #2
  4. slowcoach3
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    slowcoach3 Active Member

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    [Sep 18, 2012]
    Jesus. I'm going to replace my pick up pipe again just to be safe lol Your right about that interior Phil but hopefully you'll be going so fast when your done no-one will be able to see it....
    Russ
    #3
  5. phil miller
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    phil miller Member

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    [Sep 18, 2012]
    Lol, spitting flames aswell fingers crossed, ive been meaning to take the ARY to work to add to the scrape pile but its a nice reminder that the pick up is oh so important, will find a use for it, may teach my little boy how to take a head off and then have it somewhere to remind me to change the oil lol
    #4
  6. phil miller
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    phil miller Member

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    [Sep 20, 2012]
    Well the parts have started to arrive, time for a little update
    [​IMG]
    [​IMG]

    one the turbo is here (should be tomorrow) i will make a start on it all, cant wait, im like a kid in a sweet shop lol
    #5
  7. aragorn
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    aragorn "Stick a V8 in it!" Staff Member Moderator VCDS Map User

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    [Sep 20, 2012]
    Why keep the stock downpipe? Its a fairly horrible design!

    Get yourself a nice 3" one!
    #6
  8. phil miller
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    phil miller Member

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    [Sep 20, 2012]
    i wanted to, aswell as a relentless manifold, but as the quattro is just for a little fun i couldnt justify the cost atm, the main problem is where do you draw the line, stainless system, ko4 hybrid, new rods, its endless, the car owes me next to nothing, the goodies can come later so to speak
    #7
  9. slowcoach3
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    slowcoach3 Active Member

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    [Sep 21, 2012]
    Good work and a sensible attitude, going from 180bhp up to a potential 250/260? thats a hell of a mark up anyway! Custom map, fmic and tip-filter setup should show some pretty good results. Just a shame about the interior:drool:
    #8
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  10. phil miller
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    phil miller Member

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    [Sep 21, 2012]
    Thank you mate, the interior still gets me down, I have thought about changing it, but most I've seen are 3dr so then I'd still have to find the door cards and headlining to match, one day a 5dr interior will come up and I will replace it then, until then I will have to wear sunglasses when I'm sat in it lol
    #9
  11. coatesy
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    coatesy poking badgers with spoons

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    [Sep 21, 2012]
    meh weld the rear doors up then bosh three door ! then strip the rear out then no problem of finding interior
    #10
  12. s3dave
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    s3dave TFSI Hybrid

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    [Sep 21, 2012]
    Not sure if reesy has still got an interior maybe PM him?

    And Phil You do right not ploughing money into it, its not gospel to have all the latest mods... some people actually just want to drive the bloody things...:icon_thumright:
    #11
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  13. phil miller
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    phil miller Member

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    [Sep 21, 2012]


    Lol that's not a bad idea dude, how are you finding your new turbo install?
    #12
  14. phil miller
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    phil miller Member

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    [Sep 21, 2012]

    Ideal, thank you mate, will pm him
    #13
  15. aragorn
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    aragorn "Stick a V8 in it!" Staff Member Moderator VCDS Map User

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    [Sep 21, 2012]
    Still, getting a 3" downpipe will make it easier to attach to your existing A3 exhaust. The S3 downpipe is designed for dual cats hence the horrible Y section. Do you have the S3 cats to go with it?
    #14
  16. phil miller
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    phil miller Member

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    [Sep 21, 2012]

    Mine is a Quattro so has the dual cats already fitted dude, although it will be fun undoing the rusted round builds from the old downpipe to the cats, will get my angle grinder out lol
    #15
  17. coatesy
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    coatesy poking badgers with spoons

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    [Sep 21, 2012]
    Far to much fun :p could do with going a little bit faster lol already working on that though
    #16
  18. 666markyboy
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    666markyboy Well-Known Member

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    [Sep 21, 2012]
    I think you will find that although the TQS has dual cats that the orientation of the bolts is different so the flanges wont line up.... i know this because i fitted an S3 system to my TQS.... i got a full system off a BAM engined car and was going to fit the cats too as they looked in beter condition than mine but i had to keep the TQS ones because of this.....
    #17
  19. phil miller
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    phil miller Member

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    [Sep 21, 2012]
    Hmm, i put the quattro on the ramp today to MOT it, and the bolt pattern looks the same from my new downpipe to the cats, if its different then i will change the flanges on the cats, anyway the MOT went well, got a CV boot to do and n/s TRE, less than £20 for the parts, mot runs out on the 25 Oct so will replace them and then test it wed so will have a 13 month MOT before i fit the new parts
    Also today i cleaned out my ARY sump (its got the level sensor the AGU one hasnt so will change it when the engines out) my OH is starting to think that i planned a KO4 change from the day i bought it, i keep saying i didnt but as parcels arrive each day she cant get her head round me finding all the bits so fast, she only agreed to it a week ago (i argeed it with myself ages ago lol)
    [​IMG]

    all clean and ready for fitting
    #18
  20. 666markyboy
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    666markyboy Well-Known Member

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    [Sep 22, 2012]
    Is yours a facelift model ??? mines a 1999 so possibly that might make a difference but it definitely wouldn't mate up on mine... if you have access to welding then yeah just cut the flanges off and re-weld them in the correct place..... i always wanted to do this mod to mine but was never able to source the parts to my budget ( not very big ) good luck hope it all works out well
    #19
  21. phil miller
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    phil miller Member

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    [Sep 22, 2012]
    Yeah mines a facelift model, I've got a decent welder so will mod it if need be, I don't have a budget at all, I just seem to buy loads of bits lol, the good thing is the A3 isn't my daily, my golf is driven by the OH and our Vdub camper I use for work ( tbh I could walk to work but I enjoy driving the camper lol) so its not an issue the A3 being sat up for weeks on end

    I prices up the oil and water pipes for the turbo today and it's just over £320 for all 4, any one got any forsale????????
    #20
  22. slowcoach3
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    slowcoach3 Active Member

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    [Sep 22, 2012]
    320? You need a city loving mole in Plymouth TPS.... Theres a few S3s breaking on egay and also in the classifieds on here, have a word with them, its got to be better than that
    #21
  23. phil miller
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    phil miller Member

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    [Sep 22, 2012]

    Lol good idea, as much as I'd like to fit new I will go thro the ads and email members about them, if that still doesn't find them then will have to be evil bay

    Still good for Sunday mate?
    #22
  24. slowcoach3
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    slowcoach3 Active Member

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    [Sep 22, 2012]
    Trawling ebay sucks but it saves a fortune untill you stumble across things that you suddenly find you can't live without lol
    Yeah I'm all set for sunday, shiny new pick up pipe ready! And a raincoat
    #23
  25. solaris
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    solaris Member

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    [Sep 22, 2012]
    I know the feeling..eBay can be detrimental to funds. Good work so far by the way, I'll be watching this build :)
    #24
  26. andy 1.8t
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    andy 1.8t Member

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    [Sep 22, 2012]
    At least the drinks holder still works!:ermm:
    #25
  27. phil miller
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    phil miller Member

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    [Sep 22, 2012]
    lol, yeah i should have removed the empty before the pics lol

    Russ, it wont be raining tomorrow have faith, ive got a new tube of the sump sealer already

    Evil bay is awesome for finding odd parts, but, i find when im looking for something i find loads of bits i need, then little bad phil and angel phil sit on each shoulder, angel phil says "dont worry you will find this cheaper just wait" bad phil shots angel phil and says "dont listen, you need that NOW, and you WONT find it cheaper ever again, hit that buy it now button"

    Thats how it is i promise you LOL
    #26
  28. phil miller
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    phil miller Member

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    [Sep 22, 2012]
    well the post man dropped off a parcel (for the OH :() at 8:45, then letters at 12:30, then at 2:35 we had this

    [​IMG]

    i was like a kid in a sweet shop

    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]

    not waiting on much now, will be starting it next saturday
    #27
  29. coatesy
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    coatesy poking badgers with spoons

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    [Sep 22, 2012]
    Sweeeet! good progress mate, now just get it all boshed on.
    #28
  30. slowcoach3
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    slowcoach3 Active Member

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    [Sep 23, 2012]
    Ha Ha Ha! Couple of weeks ago Phil was being super sensible and was just going to put another k03 on it and get it running again. Oh how things change quickly! Good to see it coming on, its going to be fun when its mapped, might have found you an interior too, stocksy wants a baby proof ( wipe down ) interior so will be selling his cheap.
    Its not going to rain tomorrow so I can replace my pick up pipe, good but boring. At the moment your project is far more interesting
    #29
  31. phil miller
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    phil miller Member

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    [Sep 23, 2012]
    I think i got the rain bit a little wrong :(
    i didnt know adz had an Audi, be sweet if he does sell his old interior, just down the road and be good to catch up with him
    Im now in that awful stage, the parts are here to start the work, i wanna get started but have loads on this week so will have to wait till next saturday/sunday, but that will see it all fitted (weather permitting) im gonna bring my Turbo over for you to have a look at see what you think of it mate
    #30
  32. phil miller
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    phil miller Member

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    [Sep 23, 2012]
    Well today i went over to see slowcoach3, Russ gave me a TIP and panel filter (thank you again mate :)) i love your S3 dude

    Also i spoke to Dan and he is gonna give my turbo the once over to make sure its a solid unit, so will be packing it up to send up to him tomorrow, fingers crossed it will be back for the weekend so i can fit it
    #31
  33. slowcoach3
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    slowcoach3 Active Member

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    [Sep 23, 2012]
    Phil have you had a good read up on tolerences for play on k04's? I'm pretty sure you had a lot in yours but its always good to have a second opinion or two! Dan could always hybrid it while its there though....
    I like my S3 too :rock: pleased to be able to help on your project
    #32
  34. slowcoach3
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    slowcoach3 Active Member

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    [Sep 23, 2012]
    I won't spam your thread too much but doing the sump, pick up pipe etc in the piising rain today sucked and took hours! Never been so wet and cold lol to make it worse the sump was so clean you could eat your dinner out of it, I didn't even bother cleaning it! Changed the pick up though so now have peace of mind.
    Thanks for the sealant mate or I wouldn't have been able to do it,
    Russ
    #33
  35. Lewis583
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    Lewis583 Active Member VCDS Map User

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    [Sep 24, 2012]
    Is that a crack in the wastegate "penny" seat?

    Nice progress though bud:icon_thumright:
    #34
  36. phil miller
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    phil miller Member

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    [Sep 24, 2012]
    tbh even before id got home id textd dan asking about movement, he said that oil pressure takes it out, a little in and out is ok ish but like you said if its checked then it will be ok, so its off to Dan today, and will come back good as new (not hybrid'd tho :( as much as id love to i need to keep an eye on the costs atm)

    The weather yesterday was awful, driving back across the moor i was being blown all over the place, glad the sump was clean and its all sorted now, Jake loved it over at yours:icon_thumright:
    #35
  37. phil miller
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    phil miller Member

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    [Sep 24, 2012]
    Thank you mate, its coming together well atm
    no there isnt a crack in it, it looks like a stain tbh, although the pic makes it look alot worse
    #36
  38. coatesy
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    coatesy poking badgers with spoons

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    [Sep 24, 2012]
    haha until dan says it needs rebuilding, then you fold under the opportunity, then the build thread gets renamed to hybrid build :D

    :racer:
    #37
  39. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Sep 24, 2012]
    Soz mate but that looks like a crack to me... I don't think its gonna present too much of a problem at the moment but tbh I haven't seen a used K04 that hasn't cracked...

    This was mine when I took mine off to go BT..
    [​IMG]

    [​IMG]

    These are fairly typical cracks... and I have seen much worse on less mileage too...

    <tuffty/>
    #38
  40. phil miller
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    phil miller Member

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    [Sep 24, 2012]
    Bugger, it's now boxed up, I'm sure it wasn't cracked but now I have that little doubt in my mind it might be, will let dan have a go at it, hybrid would be nice but as I've said it would add more money to it and I wanna try and keep te spend under control lol, Saturday is when it all starts, engine out, won't take to long, just a shame I've got 4 and a half days of work before I can start on her :(
    #39
  41. aragorn
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    aragorn "Stick a V8 in it!" Staff Member Moderator VCDS Map User

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    [Sep 24, 2012]
    Mines cracked like that. I ignored it and bolted it on. It works fine.
    #40

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