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K04 Hybrid progress

Discussion in 'Audi S4/A4/A4 Cab (B7 Chassis)' started by solaris, Aug 9, 2011.

  1. solaris
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    solaris Member

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    [Aug 9, 2011]
    Hi,
    There have been loads of questions around fitting a K04 to the A4 2.0TFSi on this forum so I thought i'd have a crack at it and post up my progress.

    Parts list so far :-
    K04 Hybrid Turbo
    S3 injectors
    ATP Front Mounted Intercooler
    Custom RAI Motorsports 4" to 3" Down pipe with s3 flange
    Custom made Silcone T pipe (38mm take off to fit s3 flange)
    500cm 25mm id silcone hose
    Silcone elbow
    S3 Diverter Valve flange (06F-145-751)
    034 Motorsports Silicone Turbo hose


    With regards to fitting the actual turbo I was told that one of the ears on the hotside flange fowls the motor mount and will need to be trimmed. You can get away with grinding it slightly i'm told but I went down the route of totally trimming the ear back and re-tapping the hole. I also trimmed down the flange on the downpipe to match.

    Before
    [​IMG]

    After
    [​IMG]
    [​IMG]


    Flange trimmed/modified
    [​IMG]
    #1
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  3. CMD
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    CMD Pointing Forward's!!!!!!!!!

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    [Aug 10, 2011]
    I'm locked in to this . Well done.
    #2
  4. Marrow
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    Marrow Member

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    [Aug 10, 2011]
    Good effort mate if I had quattro I would love to do this but my front driver cant handel what its already got !
    Whats your target BHP and when are you planning on installing ?
    #3
  5. hades-
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    hades- Yorkshire & Humber Rep. Regional Rep VCDS Map User

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    [Aug 10, 2011]
    speed it up a bit
    #4
  6. hades-
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  7. solaris
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    solaris Member

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    [Aug 10, 2011]
    I'm using the revised piston type diverter valve, i'm sure it will be able to cope and plus i'm not really into my car making dump sounds and for this reason i'll be circulating the air back into the inlet hose. I'll be posting my solution as soon as i've finnished it.
    #6
  8. drmole
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    drmole Well-Known Member

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    [Aug 10, 2011]
    im very interested in this conversion aswell any chance u cud put the costs up aswell so i can budget lol
    #7
  9. hades-
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    hades- Yorkshire & Humber Rep. Regional Rep VCDS Map User

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    [Aug 10, 2011]
    mine was done all in for 2650
    thats parts exhaust hpfp upgrade live tune injectors pistons etc etc
    #8
  10. hades-
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    hades- Yorkshire & Humber Rep. Regional Rep VCDS Map User

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    [Aug 10, 2011]
    the revised will take the power well mine went depends on your psi
    you dont need the dump sound its only the spacer but that can be removed
    im relocated to the cold side then routed back to the inlet so if im not running the spacer i just pipe it back up

    also did you get the oem s3 outlet pipe
    i had nothing but trouble on my custom outlet so i got oem so it fits suug turbo side chopped the rest up and mated it to my custom pipe work
    Last edited: Aug 10, 2011
    #9
  11. drmole
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    drmole Well-Known Member

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    [Aug 10, 2011]
    was tha fitted or did u fit it urself tha sounds pretty good for all parts etc
    #10
  12. solaris
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    solaris Member

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    [Aug 10, 2011]
    If your pistons & rods have also been upgraded thats a bargin!!...I'm going to do my rods only maybe next year
    #11
  13. solaris
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    solaris Member

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    [Aug 10, 2011]
    I did not have enough clearence to use the first bit of the s3 pipe, it wasn't at the correct angle to connect upto my FMIC if I was using the side mounts it may have been ok. In the end i got a custom silcone elbow made.
    #12
  14. hades-
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    [Aug 10, 2011]
    thats what i did i ment the end that fits in the turbo
    my silcone kept popping off so i chopped the pem s3 pipe at the top so i had the good fitment and joined it to my custom
    #13
  15. hades-
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    hades- Yorkshire & Humber Rep. Regional Rep VCDS Map User

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    [Aug 10, 2011]
    my spanner man is a good mate so we used his garage and i helped quite a bit just got him wasted a few times he likes his drink
    its in there now for front upgrade and new end pipes lights etc
    #14
  16. drmole
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    drmole Well-Known Member

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    [Aug 10, 2011]
    front upgrade u going for DTM front then? i may be selling the rear bumper i have
    thas still a good price tho for all them quality parts
    gunna start looking k04's on the bay lol
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  17. hades-
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    hades- Yorkshire & Humber Rep. Regional Rep VCDS Map User

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    [Aug 10, 2011]
    yes DTM front iv had the bumper made to fit the OEM RS4 grill
    how much for the rear bumper ?
    im in barry every weekend so can pick up anytime
    iv already got the full rear fixing kit
    #16
  18. drmole
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    drmole Well-Known Member

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    [Aug 10, 2011]
    was thinking bowt 200 mark has a slight crack were it was stored before i had it but ive taken it to a bodyshop n they said its easy fix as when its fitted to the car the crack seals its self so they said a tiny bit of resin n it be sorted
    #17
  19. hades-
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    hades- Yorkshire & Humber Rep. Regional Rep VCDS Map User

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    [Aug 10, 2011]
    can you post a few pics of the damage id say crack but you know what the pervs are like on here
    oh and SOL sorry for the thred hijak
    #18
  20. drmole
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    drmole Well-Known Member

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    [Aug 10, 2011]
    lol too right yeah mate its tucked up nice and warm in the attic ill get some pics up asap and ill start a new thread as think were de-railed this one enough lol sorry SOLARIS :sorry:
    #19
  21. hades-
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    [Aug 10, 2011]
    no probs quick pm when you get the thred up
    cheers
    #20
  22. solaris
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    solaris Member

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    [Aug 10, 2011]
    Right i'll try and regain control of this thread..:sm4:

    So injectors were fitted today however the valve stems were not looking healthy.... lots of carbon build up.
    [​IMG]
    Last edited: Aug 10, 2011
    #21
  23. drmole
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    drmole Well-Known Member

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    [Aug 10, 2011]
    christ thas alot of carbon was it rning right? how many miles has she done?
    #22
  24. solaris
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    solaris Member

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    [Aug 11, 2011]
    52K miles, the car was running great, no rough idle or misfire. Think this amount of build up is normal for the amount of miles. I'm contemplating fitting a catch can to prevent this in the near future.
    #23
  25. hades-
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    [Aug 11, 2011]
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  26. solaris
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    solaris Member

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    [Sep 2, 2011]
    Pics of injectors in place

    [​IMG]
    #25
  27. solaris
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    solaris Member

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    [Sep 2, 2011]
    Out with the old K03

    [​IMG]

    [​IMG]

    [​IMG]
    #26
  28. solaris
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    solaris Member

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    [Sep 2, 2011]
    In with the new K04 Hybrid!

    [​IMG]

    [​IMG]

    [​IMG]
    #27
  29. solaris
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    solaris Member

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    [Sep 2, 2011]
    Custom K04 flange welded to the downpipe:-

    [​IMG]
    #28
  30. solaris
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    solaris Member

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    [Sep 2, 2011]
    Once the turbo was mounted the tricky bit was designing a recirculation solution for the Diverter valve. Unlike the K03 the K04 does not have a built in DV on the compressor housing. I'm not really into the whole "blow off" sound and think the car will perform better anyway if the air recirculates back into the inlet.... so here is my solution:-

    I've tapped into the silicone inlet housing and the charge pipe:-

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]
    #29
  31. hades-
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    [Sep 2, 2011]
    looking good
    good choice on the recirc mine was around the same
    but i use a spacer now
    no loss in power with spacer and without
    proven on dyno
    have you picked the tuner yet ?
    #30
  32. drmole
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    drmole Well-Known Member

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    [Sep 2, 2011]
    looking very sweet some majour clampage there did u have to make the hose's up from others?
    #31
  33. solaris
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    solaris Member

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    [Sep 2, 2011]
    Its an elbow joing onto t-piece joining onto a reducer ..I wanted to get a cutom pipe made however the costing was rediculous.
    #32
  34. solaris
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    solaris Member

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    [Sep 2, 2011]
    MRC tuning should be mapping it once it's all together. At the moment i'm having a nightmare with the ATP FMIC in that it doesn't fit behind the DTM bumper. I've trimmed the **** out of the inside of my bumper but still no joy. I ended up ordering another one, it arrived today and what a gem it is!

    [​IMG]
    #33
  35. hades-
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    hades- Yorkshire & Humber Rep. Regional Rep VCDS Map User

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    [Sep 3, 2011]
    the ic looks good
    take pics of fitting and cutting bumper plz
    also if you want that pipe custom fabbed in SS send it up to me i could get my bloke to do a fast turn around on it for you
    #34
  36. drmole
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    drmole Well-Known Member

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    [Sep 3, 2011]
    I bet I'm trying to find full hose kit water n boost but nothing like tha looks really mate is close to finished now or have u got few more things lined up before u let her loose

    Sent from my Nexus S using Tapatalk
    #35
  37. solaris
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    solaris Member

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    [Sep 3, 2011]
    At the moment i'm just sruggling with the intercooler once that is done it just needs to be mapped. I just keep getting tied up with work kids etc so hard to find time at the moment. But i will keep posting up progress.
    #36
  38. drmole
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    drmole Well-Known Member

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    [Sep 3, 2011]
    yeah my prob is cash at the more i got time in bucket loads lol loving the progress so far tho cant wait to see the finished item should give some very healthy dyno figures too
    #37
  39. Chris79
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    Chris79 On my 3rd A4! RS4 next???

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    [Sep 4, 2011]
    Guys, what kind of power are you achieving on standard internals?

    Is the intercooler upgrade required or just a nice to have?

    Reminds me of my Subaru days! Will the car retain it's standard manners with better performance?

    Chris
    #38
  40. solaris
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    solaris Member

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    [Sep 4, 2011]
    You can use the standard side mount intercoolers but if your using a hybrid k04 and are chasing figures its good to have a bigger core to deal with the increase in air flow.
    The car manners should be retained that was one of the resons for using the k04 and not going big turbo. The standard block (BUL) should be able to take 400bhp/400lbft and although this turbo is capable of achieving those figures I don't really want to map my car upto that level. I've kinda shot my self in the foot because this hybrid turbo spools very quickly in comparison to the std k04 and i'm concerned that the torque coming in so early is bound to snap rods. Surely the soulution is to limit the torque coming in so early during mapping however is that what I really want? hell no!
    #39
  41. solaris
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    solaris Member

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    [Sep 4, 2011]
    Std side mounted intercoolers removed
    [​IMG]

    [​IMG]
    #40

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