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Jay A3 KO4 build

Discussion in 'A3/S3 Forum (8L Chassis)' started by Jay A3, Dec 8, 2011.

  1. Prawn
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    Prawn My other car is a MINI!!!!

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    [Jul 17, 2014]
    if the map, maf, and injectors are the same as they were on the ko3S, it should be fuelling just fine shouldn't it?

    Or have you stuck larger injectors in already before the map jay?
  2. Jay A3
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    Jay A3 More power

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    [Jul 17, 2014]
    Don't be silly prawn, I wouldn't make such a noobie mistake. I would pm everyone first to check :p

    Yeh exactly same setup, maf and injectors on the k03s map
  3. BENJAMIN
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    BENJAMIN Active Member

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    [Jul 17, 2014]
    Lambda position is a little different, that's my thoughts.
  4. Jay A3
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    Jay A3 More power

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    [Jul 17, 2014]
    Do I need to move it to the second position? Hope not if I recall the second position is bunged and welded....
  5. aragorn
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    aragorn "Stick a V8 in it!" Staff Member Moderator VCDS Map User

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    [Jul 17, 2014]
    lambda isnt used at WOT on M3.8 AFAIK, so its not going to be lambda related.
    Jay A3 likes this.
  6. Jay A3
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    Jay A3 More power

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    [Jul 17, 2014]
    Just checked my oil and it's fine. Sitting on the max line. Looking really clean too! Been told to keep an eye on it, so I hope it simply is just over fuelling...
  7. BENJAMIN
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    BENJAMIN Active Member

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    [Jul 17, 2014]
    Weirdly it does seem to play a part on the agu as to where you position it. We've had a few issues with lambda position. On the transition between closed loop and open loop you get a puff of fuel that dissipates. Also can have an affect on trims.

    On the same token, Some agu's are more sensitive than others. I know niki has had it before. Odd!
  8. Prawn
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    Prawn My other car is a MINI!!!!

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    [Jul 17, 2014]
    AGU's are fecking odd! I've had several issues with lambda position before on my various setups.

    If the lamda is moved, it changes the trims, and it seems to apply those changes at WOT also even though it's not relying on the sensor at WOT as it's open loop. God knows if it's meant to. They do weird things at the best of times!
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  9. superkarl
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    superkarl MAN OF STEEL

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    [Jul 17, 2014]
    I ate a big red candle
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  10. BENJAMIN
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    BENJAMIN Active Member

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    [Jul 17, 2014]
    Sure it wasn't a big red rubber dildo?
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  11. Jay A3
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    Jay A3 More power

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    [Jul 17, 2014]
    Safe assumption
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  12. superkarl
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    superkarl MAN OF STEEL

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    [Jul 17, 2014]
    ****, I wondered where the wick was
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  13. Westy
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    Westy Double Dark Side! Diesel & 8P

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    [Jul 18, 2014]
    He's had that thing stood up in the middle of the dinner table for months but it would never light!
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  14. superkarl
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    superkarl MAN OF STEEL

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    [Jul 18, 2014]
    dinner party with the family and everyone was acting dead weird!
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  15. Jay A3
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    Jay A3 More power

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    [Aug 2, 2014]
    Waiting for this remap is killing me. I have been looking for something to do... Decided my headlights were looking a bit yellow and needed a bit of upgrading. Sourced a spare set from Reesy

    [​IMG]

    [​IMG]

    So firstly I removed the indicator and the levelling motor.

    *tip
    Twist the motor to become undone but don't remove it yet as it's still connected to a clip inside. Turn the adjuster at the top so it moves the light towards the rear.

    [​IMG]

    This makes it easier to remove. Tilt the motor and slide it out the clip. They have a tendency to snap but can be bought of eBay for £4 each. Easy to replace.

    [​IMG]

    Remove screws on the indicator side x 3
    [​IMG]

    Remove seal
    [​IMG]

    Pry off the 4 metal clips holding the lens on (2 top and 2 bottom)

    Pre heat the oven to 120 degrees. Place the headlight in the oven for 3-4 minutes, this will soften the silicon. Bit tricky but with a flat screw driver and a knife it will come apart.

    The light holder itself comes off by unscrewing the adjusters pushing the light out to the front as much as possible

    [​IMG]

    Everything else comes apart easily
    [​IMG]
    [​IMG]

    Took off all the chrome and with a scotch pad (picked up halfords)

    [​IMG]
    [​IMG]
    [​IMG]

    Out comes the black satin paint. Applied around 2 layers
    [​IMG]
    [​IMG]
    Put back in reverse order. Before I dropped the lens back on, I put the unit back in the oven for a few minutes to soften it up again to get a good seal.
    [​IMG]

    Word of warning the adjuster / cogs can be a bit fragile and worn. Not sure if these can be easily sourced, but luckily I had my old unit as spares

    [​IMG]

    I will get a pic with these on the motor later on today
    Last edited: Aug 2, 2014
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  16. g60leigh
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    g60leigh Well-Known Member

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    [Aug 2, 2014]
    Nice write up Jay. When will mine be ready
    Last edited: Aug 25, 2014
  17. Jay A3
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    Jay A3 More power

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    [Aug 2, 2014]
    Easy to do yourself mate ;)
  18. Jay A3
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    Jay A3 More power

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    [Aug 2, 2014]
    [​IMG]

    [​IMG]
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  19. BENJAMIN
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    BENJAMIN Active Member

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    [Aug 2, 2014]
    Nice one jay, they look great.
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  20. g60leigh
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    g60leigh Well-Known Member

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    [Aug 2, 2014]
    Definitely look better.
    A+ for effort. Go to the top of the class.
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  21. Jay A3
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    Jay A3 More power

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    [Aug 2, 2014]
    Cheers fellas :)
  22. Jay A3
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    Jay A3 More power

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    [Aug 11, 2014]
    The headlight lenses were a little scratches up so I thought I would try the meguiars restoration kit. Comes with sanding pads, plastX and a polishing head.

    [​IMG]

    [​IMG]

    Turned out nice enough, needs another go at it but impressed with the kit
  23. Prawn
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    Prawn My other car is a MINI!!!!

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    [Aug 12, 2014]
    car is looking really good Jay! Be great to see what it makes when mapped :)
    Jay A3 likes this.
  24. Jay A3
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    Jay A3 More power

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    [Aug 12, 2014]
    Yeh I can't wait to get it mapped! Currently on the hunt for some saab redtop injectors and the car is ready. Well one or 2 more oil changes.

    I'm just phaffing around with cosmetics at the moment as I'm so bored waiting...
  25. MIGGZ
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    MIGGZ nanananananananan BATMAN

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    [Aug 13, 2014]
    wow saw that kit here and never took much to it, now i know im gona get one sort my lights to look as pretty as yours :superman:
    Jay A3 likes this.
  26. Jay A3
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    Jay A3 More power

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    [Aug 13, 2014]
    It's not bad, the sand paper pads they give you isn't enough imo. But the plastX stuff works very well
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  27. Tim_Attard
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    Tim_Attard Active Member

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    [Aug 19, 2014]
    Nice one mate, k04 is very nice. cant wait to get mine mappe too!
    Jay A3 likes this.
  28. Jay A3
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    Jay A3 More power

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    [Aug 24, 2014]
    Time isn't going quick enough Tim!
  29. Neru
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    Neru Member

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    [Aug 24, 2014]
    this looks amazing, I wanna paint mine the same colour after seeing yours
  30. superkarl
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    superkarl MAN OF STEEL

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    [Aug 24, 2014]
    put your watch forward then!!
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  31. Jay A3
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    Jay A3 More power

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    [Aug 24, 2014]
    Don't think rtech would squeeze me in if I did
  32. antwan64og
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    antwan64og Active Member

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    [Aug 26, 2014]
    Any chance the new fuel pump has exposed a failing fuel pressure regulator causing a rich issue.

    Kinda like how a new clutch exposes a failing clutch master cylinder.

    Stock A3 pump flows ~ 84 Lph
    S3,TT225, LCR pump flows ~ 108 Lph
    Sytec ITP331 flows 195 Lph @ 3 bar and 174 Lph @ 4 bar
  33. Jay A3
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    Jay A3 More power

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    [Aug 26, 2014]
    I see what you mean. The new fuel pump was installed prior to the engine swap and was fine on the k03s setup. Same map, same injectors, same fpr. Only difference is the k04 turbo...
  34. antwan64og
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    antwan64og Active Member

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    [Aug 26, 2014]
    The only thing to change that could affect the tune is the o2 sensor location.

    Have you pulled your plugs to see how they look? If they're badly fouled i'd be inclined to change them.

    On any other older car i'd say just unhook the battery for 15min to reset the long term fuel but your "lucky" like me and have a dumb as f*ck ME3.8.3 Ecu.
    These reset the fuel trims everytime the car switches off, so your car probably runs fine when you first turn her on, once the o2 sensor warms up fuel trims come into play.

    If you can't move the o2 sensor I guess you'll have to wait till the tune can be leaned out and/or target AFR voltage changed.
    Jay A3 likes this.
  35. Jay A3
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    Jay A3 More power

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    [Aug 26, 2014]
    Sounds about right antwan. It doesn't smoke till the sensor is warmed up a little. I haven't checked the plugs and will do this week. Yeh deffo can't move the sensor position so it may be I just wait till the map.
  36. Jay A3
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    Jay A3 More power

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    [Aug 29, 2014]
    Last piece to the puzzle
    Sourced saab redtop injectors as my current calibra yellow tops will max out.

    [​IMG]

    Stuck them in an ultrasonic cleaner for a few cycles and job done.

    Part number: 0280150431

    All I have to do now is wait for map day...
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  37. Jay A3
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    Jay A3 More power

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    [Sep 1, 2014]
    Day 1... I will just leave this here

    [​IMG]
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  38. StaceyS3
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    StaceyS3 Well-Known Member

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    [Sep 1, 2014]
    Top work jay!

    Didnt realise this was your thread, scrolled past it god knows how many times but thought it wasnt you as wasnt white lol

    Look forward to the finished product :)
    Jay A3 likes this.
  39. Jay A3
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    Jay A3 More power

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    [Sep 1, 2014]
    Haha it's been around for a while now! Not sure there is going to be much more development on 289bhp. Got 307bhp injectors are at max and fuelling was disappearing too quick. Need to look at some 440s...
    superkarl likes this.
  40. StaceyS3
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    StaceyS3 Well-Known Member

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    [Sep 1, 2014]
    Still top result mate

    Shows how much attention to detail us fellas pay ey, just like when the mrs gets her hair cut lol

    In fairness had scrolled past it god knows how many times but theres lots of users with variations of Jay A3 ;)

    Really need to get my arse in gear and catch uo with everyone
    Jay A3 likes this.

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