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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. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    Know the feeling mate... I am off from Friday for a week to get my inlet mani on and get the car on the dyno... I can't wait!! its only been nearly 4 years LOL...

    <tuffty/>
    #41
  2. Lingo89
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    Lingo89 Member

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    Nice project mate, doing something quite similar myself. I really hope the power jump feeling after is significant!

    I have a complete five-door interior in black for sale with everything you need (seats, dash, door cards etc...) PM me if you are interested.
    #42
  3. phil miller
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    phil miller Member

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    You have a PM sir :)
    #43
  4. phil miller
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    phil miller Member

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    Well today the boost gauge from Paradox arrived (thank you mate your a star)

    And while ordering some parts for work i ordered up an oil pick up pipe and O ring, the pipe was only £7.48 +the dreaded so imho its worth changing every other oil change due to the damage it will do if it gets blocked

    [​IMG]
    #44
  5. phil miller
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    phil miller Member

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    Well the Turbo went to Dans, the report from Dan is there was no damage, was in good condition and all that it needed was the bearings replaced and the thrust washer replaced, so all in all it was a very cheap turbo that is now in tip top condition

    also my S3 MAF arrived, here is the TIP that Russ gave me, Saturday it all starts

    [​IMG]
    #45
  6. Grazam
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    Grazam Member

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    Just had a quick read through sounds very similar to what im planning when I get some cash together to sort it all out, but my manifold has developed a crack. I was wondering do you still have your old one and do you want to sell it?

    and if someone could clarify k03 and k03s mani is the same?

    PM if you want or text on 07590537004

    Thanks Graham
    #46
  7. Reesy
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    Reesy Active Member

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    I have a K03s manifold available..:sign_plug: And yes, 3 and 3s mani are the same.

    Might be worth a read of some of the later posts in my thread OP as it has most of the info if you need it.
    #47
  8. coatesy
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    coatesy poking badgers with spoons

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    If your your going to be Putting a k04 on your car you will need a k04 manifold but if your only changing from k03 to k03s you will need a k03 manifold.

    yes is is the same manifold for k03 and k03s

    And id take your number off the thread, you don't want to be getting cold calls or pictures of people's arse's sent to your phone lol.
    #48
  9. Reesy
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    Reesy Active Member

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    Perhaps he wants a picture of your arse?

    I also have a K04 manifold and downpipe!!

    K04 on a tqs is a great upgrade btw, the sort of power the car should have come with.
    #49
  10. coatesy
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    coatesy poking badgers with spoons

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    the question is do you want a picture of my arse?

    if you do that's awesome just pm me and we can sort the size of the print and weather you want it on hi-res photo paper or on a canvas.

    my pricing isn't to bad either!
    #50
  11. Reesy
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    Reesy Active Member

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    No thanks! The one you sent to the OP has already done the rounds and it's not something I want to see ever again...
    #51
  12. Vagworld
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    Vagworld Member

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    great project :yes:

    its going to be a real sleeper, my s3's running 250bhp and surprise's alot of cars, you will need some good tyres and brakes, you on 15's?
    #52
  13. Reesy
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    Reesy Active Member

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    Those are A3 16's.

    Unless the OP has upgraded, it'll have 288mm A3 brakes, and will really need as a bare minimum a set of S3 calipers.
    #53
  14. phil miller
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    phil miller Member

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    Yeah it's got 16s ATM and the 288s I'm gonna fit 312 carriers and discs, to help stop her, well the weather is sunny down here but instead of doing it on the drive I'm gonna do it at work, mainly due to the ramp and I was a little worried about the rain lol, the one thing that I didn't want to happen could, I'm in the middle of pricing up head set, bolts, big ends and rings, I'm skint ATM but while the engines out doing it won't be massive I've gotta change the sump an fit the vvt unit anyway, that way I will know the lump is tip top, can someone please talk me out of it lol
    #54
  15. phil miller
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    phil miller Member

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    Right today will go down in history as the day the whole build CHANGED, everyone said it would i know, but today i got the engine and box out and then started to price up parts, you all know where this is going, so i thought to myself, its not my daily, its a bit of fun, im spending money on a bigger turbo and remap along with other parts to fit said turbo, so i then thought if i put it all back together and say it drops a valve or starts burning oil or worse case a big end starts to knock i would be gutted, so i priced up the following

    Headset
    Bolts
    Rings
    Bigends

    Now TBH it was a lot cheaper than i thought that little lot comes to about £160 and as the engine is out now is the time to do it, so im gonna get the head off (gotta fit a VVT anyway) take the cams out, valves de-coke it, lap the valves in and fit new valve stem oil seals, aswell as clean the head up so it looks good, the bottom end im going to take the pistons out, de-coke them, fit new rings and big ends as well as hone the block, give the block a good clean and a coat of black paint (although red would show any small leaks) then im gonna replace every gasket on the engine and do afew of the vac deletes from the how 2 thread, then all hoses will be replaced with silicon hoses before putting it all back together, i figured if i spend half an hour after work on it it will only take a couple of weeks and then atleast i will know its gonna last, any thoughts please feel free to add them, as for the oil pump, im not sure on that, will prob just take it apart and check it, mains again im not 100% sure so may just check them out, i want this engine to be strong and last, and maybe able to push 290 BHP, so even tho ive got less coin than my dog i think that taking an extra 2/3 weeks before its running is the way forward, i know everyone said this would happen lol

    pictures of todays progress
    [​IMG]
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    [​IMG]
    and the old KO3s thats the cause of all of this work lol
    [​IMG]
    #55
  16. phil miller
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    phil miller Member

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    Well my Turbo came back today with a full bill of health, thank you Dan spot on, im really looking forward to putting it all together now
    #56
  17. phil miller
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    phil miller Member

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    Ok maybe i should have called this my yo yo thread as i keep changing my mind, today my turbo to downpipe and turbo to manifold studs and nuts arrived from TPS inc both gaskets, i had already decided against the rebuild for a few reasons, first off the engine was fine it was the turbo was fooked, second funds are a little low ATM and third i thought im just as well wait and when the lump needs a rebuild go hell for leather and replace everything then, so i started putting it together although i didnt have a ko4 return pipe or feed, so after fitting the mani and turbo i noticed that the feed was as good as in the correct place all good, then when i was taking the bits out the boot of the car i picked up the oil return that i had been given when i got the AGU and it looked a little different, so i offered it up and its spot on, seems the luck was with me, we had got all the work done today and my boss said i was just as well get my Audi in and start fitting the engine, while the engine is all bolted in, gotta refit the cats and connect up the coolant pipes and re connect the wiring loom
    [​IMG]
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    [​IMG]
    [​IMG]
    [​IMG]

    now i do have one problem, the turbo coolant pipe that goes around by the cambelt cover on the k04 goes to a aux water pump, the k03 one goes to a 3 way pipe connector, do i just cut the ko4 one and connect it to the same place as the ko3 one went or whats the best thing to do?

    also if anyone has an S3 cats and cat back exhaust let me know as i wanna fit this now rather than when R tech tell me my exhaust is holding the power back
    #57
  18. coatesy
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    coatesy poking badgers with spoons

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    You should take a look at aftermarket downpipes and sports cats or de-cats, they would be the best thing, especially if your going on about holding back on power.

    Good progress dude, shame you can't go all the way with the rebuild this time, but there is always plenty of time for that.
    #58
  19. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    Fit the K04 one where the K03 one goes mate... you don't have an after run pump so no need to over complicate things..

    The metal crimp on the K04 water pipe can be carefully cut (same direction as the pipe) to split it for removal... its like a 'posh' clip... the metal part of the water pipe has a swaged end so you can do the same on both the K03 hose and the K04 hose and join the rubber bit of the K03 hose to the metal bit of the K04 hose and secure with a clip... not sure which reaches but I am actually about to do a similar conversion to a customers 180 TT...

    <tuffty/>
    #59
  20. Grazam
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    Grazam Member

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    Its all looking good, happy days with the build its coming along nicely. :)
    #60
  21. phil miller
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    phil miller Member

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    Ideal will cut the posh clip off and do it that way, fingers crossed will be able to fire it up soon

    im gonna fit a FMIC with 3in in and outlets is there universal kit you can buy for the pipe work or has someone got all the info to get it from somewhere like ASH?
    #61
  22. phil miller
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    phil miller Member

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    well today i had a stroke of luck, i have been given a FMIC (winner) so anyway here it is, what do you think?

    [​IMG]
    [​IMG]
    [​IMG]

    so can anyone post a link to a pipe kit so i can connect it all up?
    #62
  23. aragorn
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    aragorn "Stick a V8 in it!" Staff Member Moderator

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    If your dismantling the engine, RODS!
    #63
  24. phil miller
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    phil miller Member

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    ive had a bit of a re think, by the time id replaced the bearing, rings, rods, maybe valve guides, cut the valve seats the whole lot had got a little out of my price range atm, one day a full rebuild will be on the cards
    #64
  25. phil miller
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    phil miller Member

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    been a while since i updated this, the engine is all in and running, ive ordered up my FMIC pipes from mrsilicone of ebay, using Prawns post in the sticky i ordered up the same pipe work so i can crack on with that

    i removed the bumper and crash bar, cut the crash bar so the intercooler will fit, and then cut and welded some mounts, id bought some off paradox but i had to change them slightly

    so today i finally bolted up my intercooler but had a massive blonde moment, the stay that goes from the under side of the slam panel to the crash bar, while i decided to use the saw at work and cut it off near the top, everything was going well until i slipped.......then got a face full of R134 caught the fooking AC rad :(, still not sure what to do, i could had it ally welded as i just caught it, defo not gonna buy a new one though

    the front mount
    [​IMG]
    [​IMG]
    [​IMG]
    #65
  26. s3dave
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    s3dave TFSI Hybrid

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    Have you tried the bumper on yet Phil? The IC looks far to far forward?
    #66
  27. phil miller
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    phil miller Member

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    I offered it up and im not sure how much of the lower centre grill i can keep, its a deep intercooler, it is as close to the AC rad as can be, its only 88mm but that is a little bigger than the welly they sell on the bay which is 76, here is the link FMIC FFRONT MOUNT TURBO INTERCOOLER TYPE B 600x300x76MM | eBay

    i may end up without the lower half of the bumper lol
    #67
  28. Grazam
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    Grazam Member

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    lol its looking good still just a few more bits to do
    #68
  29. 16Klappe
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    16Klappe Princess Slayer

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    Why you no update? :p

    [​IMG]
    #69
  30. Prawn
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    Prawn My other car is a MINI!!!!

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    You need to update this more often :laugh:
    #70
  31. badger5
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    badger5 RIP S3dave Site Sponsor

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    One Word
    HEATSHIELDING
    #71
  32. 16Klappe
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    16Klappe Princess Slayer

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    I think that is actually two words squished into one :p

    Phil isn't updating so I will quickly. Heat shield material has been ordered and we will be replicating Prawns setup as soon as it arrives, we got the same stuff off Merlin. Phil has also got a tidy enclosed heat shield for his filter and one for me for christmas :p
    Last edited: Dec 22, 2012
    #72
  33. Prawn
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    Prawn My other car is a MINI!!!!

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    I've already said this Bill :) I'm assured it's in hand :)
    #73
  34. phil miller
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    phil miller Member

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    Lol, sorry for the lack of updates

    Ok, where to to start, right the intercooler is all piped up :), i bought Prawns winifold off Dave, fitted a boost gauge, fitted a catch tank, MOTd her, the DVLA decided to fine me £260 this morning :( (parked on the road no tax=my own fault)
    She is booked in at RTech on the 31 jan for a custom remap, ive mainly been posting on FB but here are some pics :)
    [​IMG]
    [​IMG]
    [​IMG]
    Prawn was the life saver when i was ordering my pipes, saved a massive amount of hassel

    [​IMG]
    Just fits behind the bumper, although i did have to trim loads off the back of the bumper
    [​IMG]
    my V1 winifold, with true RACECAR history :)
    [​IMG]

    Jardo found me a Baileys dv30 but niki wants this changed to a 007p
    Rach has ordered me a V2 DP and decat (which is very nice of her)

    all thats left is injectors, wmi and a TIP
    #74
  35. superkarl
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    superkarl MAN OF STEEL

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    Why does niki want a 007p on??
    #75
  36. phil miller
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    phil miller Member

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    I dont know, all i can think is he has had problems with baileys in the past
    #76
  37. 16Klappe
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    16Klappe Princess Slayer

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    Niki told me (I have been dealing with Niki to confirm spec on Phils behalf) that whilst DV30's pass the bubble test and seem fine he has seen them open on the dyno. Ben and Jim couldn't actually give me a reason why Phils brand new DV30 wasn't up to the job, but if they say change it then we will get Phil a 007p.

    It is badly timed because only last week I sold my 007p and all the springs, I would have happily swapped it for the Baileys.
    #77
  38. phil miller
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    phil miller Member

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    Just had an email from Merlin, my heat shield sheet has been sent, CAD coming on very soon :)
    #78
  39. superkarl
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    superkarl MAN OF STEEL

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    Fit an oem.
    EspecIally after all recent tests and discussions it should be top of the list
    #79
  40. phil miller
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    phil miller Member

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    Niki says he wants a 007p so will beg steal or borrow one for the week while its there and then decide what to do after that :(
    #80

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