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I want to do a K04 upgrade

Discussion in 'A3/S3 Forum (8L Chassis)' started by djdougalno1, Sep 27, 2009.

  1. djdougalno1
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    djdougalno1 Member

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    [Sep 27, 2009]
    right hi all ive got a3 quattro t sport 99 engine code ajq also just brought a tt engine cutout of smashed car engine code apx can any one help me an tell me everything i need to swop over to do the upgrade to k04 and if any modifictions are needed :yellowrs4::arco:
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  3. voorhees
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    voorhees Moderator Staff Member Moderator

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    [Sep 27, 2009]
    Hello and Welcome to the site
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  4. Dani_B19
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    Dani_B19 Audi-sports own special child.

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    [Sep 27, 2009]
    A fair bit.
    3"DP, Cat and exhaust system, exhaust manifold and new Tip all specfic to a ko4.
    3" Maf i.e S3, new airbox/induction kit to suit and obviously the ko4 hybrid.
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  5. djdougalno1
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    djdougalno1 Member

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    [Sep 27, 2009]
    what about the inlet manifold also my car is drive by wire so is the new inlet will it be a straight swap
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  6. Dani_B19
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    Dani_B19 Audi-sports own special child.

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    [Sep 27, 2009]
    Personaly im going for an uprated inlet, im going for a SEM with 70mm TB. If i was you just keep your inlet but if swapping go for the SEM, wouldnt bother with the s3 inlet as youll get no gains.
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  7. S3KO4
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    S3KO4 Member

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    [Sep 27, 2009]
    Hello, here is what you would probaily need plus a few other bits.. feel free to correct me if I am wrong, as I am not 100% sure

    From an S3 210/225 or TT 225 you would need:

    Exhaust manifold
    Down pipe
    Injectors
    Fuel pump
    MAF (original should work)
    ECU remap
    Induction hose

    maybe some other minor bits, but those are the main bits, a friend of mine has done similar conversion on an AGU, FWD, what a car, mapped by MRC, this thing flies.. light and powerful..

    Good luck
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  8. marcyp
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    marcyp Only me

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    [Sep 28, 2009]
    depending on you engine code you might not need injectors or the pump as you'll already have a 4bar fuel reg and maybe large injectors, no point changing the inlet as youll have to move everything to the other side i.e. wiring and run a different fmic or twin smic, you do need the tip from the tt and the 3" maf wouldnt wurry about the air box just use a good cone filter and a 3" cold air feed, glad to see you came over here from fendubbers if you need a hand or anything just let me know because im only from the other side of town :icon_thumright:
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  9. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Sep 28, 2009]
    All of the above plus....
    Oil and water lines as they are different on a K04 to a K03, TIP (induction hose) for an S3/TT 210/225. 3" MAF housing (your MAF sensor should be fine), if you plan to use the TT inlet mani then you will need to re think the charge pipe plumbing as the TT/S3 throttle body is on the other side to the A3 so you will need to extend the wiring for the TB to the other side as too the IAT sensor.

    Talking of pipe work, the K03 charge pipe setup is different to that of the TT/K04... if you plan to use the charge pipe system from the TT then you will need to think this out and the best solution would be to fit a FMIC (recommended anyway on a mapped K04).

    If you are doing something with the intercooler then you will also need to relocate the MAP sensor (if you have one and currently located in the top of the existing SMIC).

    Not a small amount of work but the end result is all good...

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

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    [Sep 28, 2009]
    Not sure you will get any from the SEM on a K04 either my friend... the K04 simply doesn't flow enough to warrant the expenses IMO...

    Unless you go BT and are chasing numbers then stick to the OEM inlet mani. I am running a std S3 inlet on my GT3071R, should be getting mapped this coming weekend if all things work out right...

    <tuffty/>
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  11. marcyp
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    marcyp Only me

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    [Sep 28, 2009]
    tuffty cant wait to see yours run! i was going to go for a hybrid k04 but dont know what fmic to go for dew to the piping size, as on the plus side pace products and pro alloy are only up the road from mine so i guess i could always get somthink custom made
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  12. Paul @ Unit 9 Remaps
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    Paul @ Unit 9 Remaps Site Sponsor Site Sponsor

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    [Sep 28, 2009]
    the op, this is also my plan later down the line
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  13. Dani_B19
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    Dani_B19 Audi-sports own special child.

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    [Sep 28, 2009]
    Will be with a ko4 hybrid and high flow exhaust maniold though. After a bit of time on sc.net ive read about a few who have them and seem to have gained on ko4's. know im no going to see massive gains like i would if i was running a BT but i will see some gains, plus its only £600-700 :).
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  14. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Sep 28, 2009]
    For the money you are considering spending, you may be better off putting it towards a GT2871 (or GT28060 maybe) and mani as a bang for buck...

    I suspect the gains you get from marrying a SEM to a K04 (hybrid or otherwise) will only gives a little gain in the midrange... the K04 just hasn't got the puff for power throughout the rev range as far as I know... I might have a word with Bill about it and see what he reckons..

    I am not suggesting that you won't get anything out of fitting a SEM but as a bang for buck mod, its a little overkill for not much real world difference... but then thats my take on mods anyway as you know :)

    @djdougalno1, soz to kinda hijack your thread but the discussion is at least sorta relevant to what you want to do :)

    <tuffty/>
    Last edited: Sep 28, 2009
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  15. emery1990
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    emery1990 Active Member

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    [Sep 28, 2009]
    That sounds like a pretty big job for the work, might aswell even save that money and sell your car towards the s3? after speaking mark from cr turbos he can hybrid my turbo to 280-300bhp for £500. not sure what the range of power will be like though. awaiting the email to find out about the how the powers down etc. i relise ill need new injectors, fuel regulators etc though, and a bit more aswell.!
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  16. Dani_B19
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    Dani_B19 Audi-sports own special child.

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    [Sep 28, 2009]
    I know what you mean tufty but i just dont know if i want togo BT, i was trying todo as much as possible to get the gains but like you say the cost may not be worth the gains compared to the BT route.
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  17. marcyp
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    marcyp Only me

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    [Sep 28, 2009]
    what is the best bang for buck then when you dont have a k04 mani to start with?
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  18. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Sep 28, 2009]
    CR Turbos K04 hybrid with K03 fitment... comp housing is K04, hotside is K03... fits onto existing A3 mani and uses existing A3 DP...

    <tuffty/>
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  19. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    [Sep 29, 2009]
    SEM and 70mm t'body on smallport is marginal gain if any IMHO
    Its wrong handed for your A3, but ok for S3/TT/ibiza 210/225/150 motors so some wiring unwrapping for t'body & ait and map sensor wiring extension will be req'd

    Depends if you have plans down the line for more than a k04 power delivery.. in which case the 210/225 motor you are installing is not really much better than the one in their now.

    Add rods to your existing motor, and it will cope fine.
    cheapest/easiest route to k04 power is sending your K03s to the likes of CR or turbo dynamics and getting it hybrided into a K04+ (RS6 K04 internals and beyond) - no charge pipework changes to make, retain oil & coolant lines, fit a silicon TIP, adapt up to the 80mm MAF with suitable induction, fit some LCR/S3/Tt injectors and mapping and you will be up with the S3's in power terms.

    a few options
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  20. emery1990
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    emery1990 Active Member

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    [Sep 29, 2009]
    Thats what im looking into what badger just said, was told 280-300bhp, thats fast enough for me in an a3. what do you mean beyond?

    and its £500 to uprate your turbo to the above.
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  21. bansheeboyo
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    bansheeboyo Member

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    [Sep 29, 2009]
    so this turbo you speek off
    is it equal to a hybrid k04????
    ah well k04 bought now so its going on
    #20
  22. emery1990
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    emery1990 Active Member

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    [Sep 29, 2009]
    i thought you had a k04 on anyway. yer but if youve already got it itll have better torque and you may be able to get that convertedto a k04 hybrid. Worth asking cr turbos. If it gives better results than the k03 hybrid then ill see about the k04 youve got.
    #21

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