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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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    Wish I'd known that you were going, I would have loved to join you.
  2. spider74
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    spider74 Member

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    Sorry mate, next time? I wasnt the organiser this time round and just tagged along with a load of lads from the UK, germany etc.

    here is another photo!
    [​IMG]
  3. Craig Cull
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    Craig Cull Active Member

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    Love this thread!! so much detail and acuracy!! cant wait to do it myself :)
  4. olethalb
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    olethalb Member

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    i've just joined and this is my first post :blush:

    firstly i'd like to thank solaris and spider for the informative posts and pics :thumbsup:

    i've just started doing this conversion myself on my DTM, i've already done the basic stuff, wheels, coils, milltek, S4 front brakes, ATP 3" decat, autotech HPFP - although i have now got my hands on APR pump.

    i've got s3 injectors waiting to go on with the turbo i'm hoping tomorrow. i've got a lot of helpful tips from this thread that have helped me along and hopefully make fitting easier.

    i've gone a slightly different route with the k04 outlet though anf made my own FMIC set up. (i'll dump updates from another forum)

    cut off original outlet and welded on k04-023 oulet from this
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    to this
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    so i can use this pipe (intended for 225 TT)
    [​IMG]
    spider74 likes this.
  5. olethalb
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    olethalb Member

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    i bought a core intended for another Audi and with a variety of bends mocked up the boost pipe run. also the FMIC had to fit without modifying or cutting the car / bumper in any way.

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    coldside boost pipe with map sensor flange and dv flange
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    painted
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    painted fmic pipes to keep them hidden in side grills
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    bolted up
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    coldside pipe fitted
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    trimmed down the silicon 90 elbow and fitted up
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    coldside done, test fit bumper
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  6. olethalb
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    olethalb Member

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    hoping to get it all bolted up tomorrow and complete the hotside boost pipes, pics to follow :yahoo:
  7. Chris79
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    Chris79 On my 3rd A4! RS4 next???

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    Excellent work! Have you fabricated the metalwork yourself?

    Is it an S3 intercooler?

    Chris
  8. olethalb
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    olethalb Member

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    it's from a B6 toyo **** kit, i bought a variety of bends and cut them all to length and taped the joins as i went then took it to my ally welder, i can mig weld but not got a tig yet unfortunately :(
  9. solaris
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    solaris Member

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    You've done a fantastic job on the charge pipe flange, that should make life easier. Also happy to see the intercooler pipes in black..nothing worse than a blinging Audi.
  10. olethalb
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    olethalb Member

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    thanks bud

    well it's been a long day, and made some good progress [:)]
    first test fit
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    hotside boost pipe run
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    turbo fitted
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    lines
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    dv fitted
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    fitted the S3 injectors and APR HPFP and tidied it all up and gave it a wipe over, excuse the intake - long story
    [​IMG]
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    oh and a pic of my 'rattle'
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    [​IMG]
    all done now just waiting remap
  11. spider74
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    spider74 Member

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    Excellent job there! Well done! Can't believe I missed this! Some great pipe work. Mine still drives great! Can't wait to see what figures you get. Chosen a mapper yet? MRC tuning did a great job on mine, can't recommend them enough.
  12. razza1
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    razza1 Well-Known Member

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    Very jealous of you guys...looking good there!
  13. olethalb
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    olethalb Member

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    thanks chaps, been at MRC all day, the car was a little low for the rollers, then the APR pump wasn't performing so luckily i bought my spare autotech and they switched it over.

    it finally made 331 and 348ft lbs, they were surised it didn't make more, unfortunately i had to stop on the way for fuel at esso and had to fill u with 'supreme' 97 ron and the intake temps were getting high.

    it seems the reason it may have been lower cam on the drive hom when i jumped on the m40 and popped it in 6th and the clutch instantly slipped when i applied the power.
  14. spider74
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    spider74 Member

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    been there mate! on both the Esso fill up and the clutch! First time i took my DTM to get mapped i put esso "premium" in it as i was running late. Was laughed at for being so daft! (lesson learned!) Also when i had my B7TDI the clutch was slipping all over on the rollers too! Just shows you need to have the car in tip top condition and even then things you didnt know about will get in the way!

    Car looks great though and i bet once you get the new clutch in it will be flying! I put a new standard clutch in mine and its been fine but Solaris went uprated. I suppose it depends how far you want to take the power?

    Anyway good stuff and now the thread has three different K04 installs!
  15. olly quattro
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    olly quattro Member

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    is that intercooler one of teh unes currently available on ebay for a b6 1.8t quattro?
  16. solaris
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    solaris Member

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    I was about to ask you about your clutch however im ever so glad I addressed this issue during my build. FYI I went for a Southbend Stage 3 inc a single mass light weight flywheel. Its been fantastic to date and never slipped even during some violent launches!

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