1. This site uses cookies. By continuing to use this site, you are agreeing to our use of cookies. Learn More.

K04 Conversion On Audi A3 AGU HELP PLEASE !!!

Discussion in 'A3/S3 Forum (8L Chassis)' started by Chester999, Jul 2, 2012.

  1. Chester999
    Offline

    Chester999 Speed Freak !!!

    Joined:
    May 23, 2012
    Messages:
    236
    Likes Received:
    2
    [Jul 2, 2012]
    Does anybody know if the k03 oil and water feeds will fit the k04 on an audi a3 agu engine or will i have to buy all new ones??
    Last edited: Jul 2, 2012
    #1
  2. Ads

    Ads

    [Sep 18, 2014]

  3. camerontarver
    Offline

    camerontarver Member

    Joined:
    Dec 30, 2011
    Messages:
    109
    Likes Received:
    4
    [Jul 2, 2012]
    your need ko4 oil and water feeds, the ko3 ones will not fit. so ive been told
    #2
  4. Chester999
    Offline

    Chester999 Speed Freak !!!

    Joined:
    May 23, 2012
    Messages:
    236
    Likes Received:
    2
    [Jul 2, 2012]
    ok cheers mate do you know if any of them will fit i have been told that the oil drain wont fit but do you know if any of the others will fit thanks
    #3
  5. aragorn
    Offline

    aragorn "Stick a V8 in it!" Staff Member Moderator VCDS Map User

    Joined:
    Jan 30, 2008
    Messages:
    15,571
    Likes Received:
    313
    [Jul 2, 2012]
    The issue is the turbo sits in the different place, meaning the length and position of the connections all change, and because most of the original lines are rigid pipe even if they were long enough you cant really bend them back into shape anyway.
    #4
  6. Lemon S3
    Offline

    Lemon S3 Alex

    Joined:
    Sep 1, 2009
    Messages:
    1,318
    Likes Received:
    9
    [Jul 2, 2012]
    Yeh you will need the K04 pipes, I think I have some spare if you need them.
    #5
  7. Prawn
    Online

    Prawn My other car is a MINI!!!!

    Joined:
    Dec 8, 2006
    Messages:
    9,584
    Likes Received:
    1,346
    [Jul 2, 2012]
    yup, having recently done this myself, the k03 lines will not fit at all, oil, water, you need them all.
    #6
  8. Chester999
    Offline

    Chester999 Speed Freak !!!

    Joined:
    May 23, 2012
    Messages:
    236
    Likes Received:
    2
    [Jul 2, 2012]
    yeah need the ko4 pipes then let me know if you have any spare lemon s3 cheers mate.
    #7
  9. Chester999
    Offline

    Chester999 Speed Freak !!!

    Joined:
    May 23, 2012
    Messages:
    236
    Likes Received:
    2
    [Jul 2, 2012]
    cheers prawn saved me some time messing about with all the old ones will get all new ones cheers again.
    #8
  10. Prawn
    Online

    Prawn My other car is a MINI!!!!

    Joined:
    Dec 8, 2006
    Messages:
    9,584
    Likes Received:
    1,346
    [Jul 2, 2012]
    the nature of this topic begs the next question to be asked also I feel.....

    Do you have the right MAF and injectors for the ko4?
    #9
  11. Chester999
    Offline

    Chester999 Speed Freak !!!

    Joined:
    May 23, 2012
    Messages:
    236
    Likes Received:
    2
    [Jul 2, 2012]
    yeah i have a 3" vr6 maf housing on the way which ill put my AGU sensor in (thanks Prawn) and was gonna go for 440cc green top injectors. i have xs power manifold brand new k04-023 turbo a 3" relentless downpipe and decat fmic coldside intake waiting for badger 5 to get some more blue 3" TIP in looking to get about 300bhp do you think this will be poss?
    #10
  12. Prawn
    Online

    Prawn My other car is a MINI!!!!

    Joined:
    Dec 8, 2006
    Messages:
    9,584
    Likes Received:
    1,346
    [Jul 2, 2012]
    Ah, sound news. So often people buy complete setups with an S3 mAF and injectors and want it to work on the AGU, when it just wont!

    If you've got a brand new turbo then you have a good chance of making good figures, the AGU has higher compression and a large port head which also helps loads. Niki has seen 300bhp from one car that was in good health, although 290ish is more realistic, but who knows!

    Who are you planning on getting to map it? and what FMIC do you have?
    #11
  13. Chester999
    Offline

    Chester999 Speed Freak !!!

    Joined:
    May 23, 2012
    Messages:
    236
    Likes Received:
    2
    [Jul 2, 2012]
    its just a ebay fmic mate with 2.5 inch pipes says it was capable of 600bhp but who knows with ebay would it be worth upgrading it or not? And not to sure about the mapping yet was thinking about r tech.
    #12
  14. Prawn
    Online

    Prawn My other car is a MINI!!!!

    Joined:
    Dec 8, 2006
    Messages:
    9,584
    Likes Received:
    1,346
    [Jul 2, 2012]
    So long as the pipes are 2.5''. Sounds like it could be the toyosports kit with a reasonably small core?

    You'd be very well off keeping the pipes, but replacing the core with the larger toyosports type B known as the Wellycooler, it's easy to cut into your existing pipework, using the core and two 76-63mm reducers.

    The smaller core will not be up to the job of cooling a ko4 flat out. Westy can confirm this, as he gained 25lbft going from the small core to the large one!
    #13
  15. Chester999
    Offline

    Chester999 Speed Freak !!!

    Joined:
    May 23, 2012
    Messages:
    236
    Likes Received:
    2
    [Jul 2, 2012]
    ok will look into getting a new bigger core then thanks for the info prawn. Quick question have you ever had to rotate your housing on your turbo mine doesnt seem to sit right?
    #14
  16. Prawn
    Online

    Prawn My other car is a MINI!!!!

    Joined:
    Dec 8, 2006
    Messages:
    9,584
    Likes Received:
    1,346
    [Jul 2, 2012]
    The ko4 outlet sits differently to the ko3, the ko4 outlet points backwards slightly compared to the ko3, like this:

    [​IMG]

    [​IMG]

    If you clock the housing round to get the outlet facing the wrong way, the actuator bracket won't fit any more!

    Best solved by working out what you need to change and getting a new bit of silicon to join up.

    Post a pic of your current setup and we can try and work out what's required
    #15
  17. Chester999
    Offline

    Chester999 Speed Freak !!!

    Joined:
    May 23, 2012
    Messages:
    236
    Likes Received:
    2
    [Jul 22, 2012]
    Cheers for your help prawn got there in the end lol thought i would post a pic of my k04 conversion still not finished but getting there.
    #16
  18. Prawn
    Online

    Prawn My other car is a MINI!!!!

    Joined:
    Dec 8, 2006
    Messages:
    9,584
    Likes Received:
    1,346
    [Jul 22, 2012]
    Where's the pic then :laugh:
    #17
  19. Chester999
    Offline

    Chester999 Speed Freak !!!

    Joined:
    May 23, 2012
    Messages:
    236
    Likes Received:
    2
    [Jul 22, 2012]
    wont let me upload it says its the text is too long do i have to make the pic smaller?
    #18
  20. Prawn
    Online

    Prawn My other car is a MINI!!!!

    Joined:
    Dec 8, 2006
    Messages:
    9,584
    Likes Received:
    1,346
    [Jul 22, 2012]
    what text mate?

    All you should have is a .jpg link, which you put in tags and it'll pop up :)
    #19
  21. Chester999
    Offline

    Chester999 Speed Freak !!!

    Joined:
    May 23, 2012
    Messages:
    236
    Likes Received:
    2
    [Jul 22, 2012]
    #20
  22. Chester999
    Offline

    Chester999 Speed Freak !!!

    Joined:
    May 23, 2012
    Messages:
    236
    Likes Received:
    2
  23. Chester999
    Offline

    Chester999 Speed Freak !!!

    Joined:
    May 23, 2012
    Messages:
    236
    Likes Received:
    2
    [Jul 22, 2012]
    there we go lol quick couple of questions prawn. When i bought my car (Audi a3 1998 1.8t AGU) it had a 195bhp oettinger chip in it on the k03 i have now done the k04 conversion and know that i will need a remap but will i do any damage running it how it is (before the remap) or will it be ok just not running 100%? And went for a little drive after i had done conversion everthing seemed fine the engine was running sweet i drove about 10-15 miles and my brake pedal just went rock soild and hardly works at all any ideas mate?
    #22
  24. Prawn
    Online

    Prawn My other car is a MINI!!!!

    Joined:
    Dec 8, 2006
    Messages:
    9,584
    Likes Received:
    1,346
    [Jul 22, 2012]
    brake pedal going solid will be a servo line failled. Either something come off between the inlet and the servo, or potentially a bigger issue could be a melted hard line behind the turbo.

    Have you added any extra heat shielding in the engine bay for the new turbo? You need to add LOTS to the A3 engine bay to keep it safe from fire, there are some important lines running across the bulkhead, and bolting on a ko4 with relentless manifold is sure to cook several of them if unprotected. the standard heat shield isn't enough.

    Also, with regards to driving it, what injectors and MAF do you ahve in currently?

    The mAF tube in your pic above looks big, and if it's unmapped, that'll be running lean as hell on stock injectors. if you've already put bigger injectors in, then it'll all be to cock and who knows what it's doing!

    If you want to drive it at the moment before it's been mapped, what you need to do is sleeve and refit your stock 70mm MAF tube, and refit your stock AGU injectors.

    Then unplug the N75 electrical plug leaving the pipes plumbed in. That'll drop boost to actuator pressure, around 6psi, which shuld stop it from blowing up.

    With that MAF tube, and the N75 plugged in, if you floor it, it WILL blow up, maybe not instantly, but it won't take long at all to destroy it :(

    Who's mapping it? and when?
    #23
    antwan64og likes this.
  25. Chester999
    Offline

    Chester999 Speed Freak !!!

    Joined:
    May 23, 2012
    Messages:
    236
    Likes Received:
    2
    [Jul 22, 2012]
    thanks again prawn your a legend it was the plastic pipe coming off the servo to the inlet had melted will replace with some rubber metal braided hose and more heat shielding where did you get your hest shield from cant find any as good as yours? And i currently have my standard injectors in but have put the bigger maf on so ill swap back for now then till i get it mapped. Was gonna go to r tech for the map but want to get clutch,flywheel and cambelt water pump done etc before.
    #24
  26. Chester999
    Offline

    Chester999 Speed Freak !!!

    Joined:
    May 23, 2012
    Messages:
    236
    Likes Received:
    2
    [Jul 22, 2012]
    What would be the best clutch for my setup and will the clutch bolt straight on ?
    #25
  27. Prawn
    Online

    Prawn My other car is a MINI!!!!

    Joined:
    Dec 8, 2006
    Messages:
    9,584
    Likes Received:
    1,346
    [Jul 22, 2012]
    If you havn't already, take a look in my build thread around Mid Jan of this year and I put up detailed pics of all the heat shielding I added. I have the double layer stuff from merlin Motorsport, not cheap, but very effetive. If it's been melting things at the back of the bay already I'd get it done ASAP.

    As for your MAF, change back to stock ASAP. If you're new tube is 80mm, you'll be underfuelling by around 38%! scary ****.

    As for the clutch and flywheel, what you want is an ABF flywheel, and a VR6 clutch. Use the flywheel bolts from an ABF as well, and the whole lot will drop straight on without any messing around. It's ligther than standard, gives a lighter pedal feel, and will hold over 300lbft.
    #26
  28. Chester999
    Offline

    Chester999 Speed Freak !!!

    Joined:
    May 23, 2012
    Messages:
    236
    Likes Received:
    2
    [Jul 23, 2012]
    Right got some braided pipe and heat shielding on the way have changed my maf back to standard with sleeve on will be looking out for vr6 clutch and abf flywheel then having cambelt and water pump done then off to r tech for the map. Prawn what did you do about the turbo bracket that sits on the bottom of the turbo and bolts to the engine my new turbo did not come with one and the one off my k03 will not fit??
    #27
  29. Prawn
    Online

    Prawn My other car is a MINI!!!!

    Joined:
    Dec 8, 2006
    Messages:
    9,584
    Likes Received:
    1,346
    [Jul 23, 2012]
    Find one from a ko4 car mate. Just message someone breaking a car on ebay and see if they will sell you the bracket only
    #28
  30. Neru
    Offline

    Neru Member

    Joined:
    Jan 21, 2012
    Messages:
    129
    Likes Received:
    9
    [Jul 23, 2012]
    What heat shielding did u buy
    #29
  31. Chester999
    Offline

    Chester999 Speed Freak !!!

    Joined:
    May 23, 2012
    Messages:
    236
    Likes Received:
    2
    [Jul 23, 2012]
    #30
  32. Neru
    Offline

    Neru Member

    Joined:
    Jan 21, 2012
    Messages:
    129
    Likes Received:
    9
    [Jul 24, 2012]
    Cheers man, do you which parts need the additional shielding and your engine bay looks good
    #31
  33. Chester999
    Offline

    Chester999 Speed Freak !!!

    Joined:
    May 23, 2012
    Messages:
    236
    Likes Received:
    2
    [Jul 24, 2012]
    cheers mate my engine bay is getting there but not finished yet lol you want to make sure you shield the brake servo the turbo outlet pipe and all the pipes at the back of the engine ive already melted the brake pipe coming off the brake servo to the inlet manifold so make sure you shield it all good.
    #32
  34. Prawn
    Online

    Prawn My other car is a MINI!!!!

    Joined:
    Dec 8, 2006
    Messages:
    9,584
    Likes Received:
    1,346
    [Jul 24, 2012]
    everything needs a heat shield man! otherwise it'll BURN!!!!

    Take a look at my build thread. I put one large heat shield right across the back protecting all the hard lines, and another coming round to the side to protect the servo
    #33
  35. Chester999
    Offline

    Chester999 Speed Freak !!!

    Joined:
    May 23, 2012
    Messages:
    236
    Likes Received:
    2
    [Jul 24, 2012]
    Alright prawn i have managed to get hold of a VR6 clutch and ABF flywheel off of someone on here called slowcoach3 for an amazing price of £50 including postage cheers mate have not recieved yet but should be here soon only problem is no ABF flywheel bolts do you know where i can get some from ???
    #34
  36. Chester999
    Offline

    Chester999 Speed Freak !!!

    Joined:
    May 23, 2012
    Messages:
    236
    Likes Received:
    2
    [Jul 24, 2012]
    and going to order the wellycooler aswell is it worth upgrading all the intercooler pipes to 3" dont think mine are even 2.5" ???
    #35
  37. aragorn
    Offline

    aragorn "Stick a V8 in it!" Staff Member Moderator VCDS Map User

    Joined:
    Jan 30, 2008
    Messages:
    15,571
    Likes Received:
    313
    [Jul 24, 2012]
    get the bolts from Audi/VW

    2.5" cooler pipes are useful, 3" is overkill.
    #36
  38. Chester999
    Offline

    Chester999 Speed Freak !!!

    Joined:
    May 23, 2012
    Messages:
    236
    Likes Received:
    2
    [Jul 24, 2012]
    ok cheers mate does anyone know the part number for ABF flywheel bolts and will be getting 2.5" intercooler pipes with the wellycooler then.
    #37
  39. aragorn
    Offline

    aragorn "Stick a V8 in it!" Staff Member Moderator VCDS Map User

    Joined:
    Jan 30, 2008
    Messages:
    15,571
    Likes Received:
    313
    [Jul 24, 2012]
    When i fitted my solid flywheel i used N 90206103, thats on an A4, but i believe they all use the same bolts for solid flywheels, 19.5mm long.
    #38
  40. Prawn
    Online

    Prawn My other car is a MINI!!!!

    Joined:
    Dec 8, 2006
    Messages:
    9,584
    Likes Received:
    1,346
    [Jul 24, 2012]
    As kev said above, flywheel bolts: vw part no: N90206103 x 6, and clutch pressure plate bolts. vw part no: N10101001 x 6.

    2.5'' IC pipes are fine for twice the BHP you'll be pushing, and far easier to fit than 3''. take a look on the FMIC thread page 9 or 10 for my write up and list of parts you'll need.
    #39
  41. Chester999
    Offline

    Chester999 Speed Freak !!!

    Joined:
    May 23, 2012
    Messages:
    236
    Likes Received:
    2
    [Jul 24, 2012]
    Right got some flywheel bolts and clutch pressure plate bolts on the way cheers lads prawn whats the fmic thread called cant seem to find the right one mate???
    #40

Share This Page