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K04 Hybrid progress

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

  1. solaris

    solaris Member

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

    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]
     
  4. Craig Cull

    Craig Cull Well-Known Member

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

    olethalb Active 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.
  6. olethalb

    olethalb Active 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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    [​IMG]
    [​IMG]
     
  7. olethalb

    olethalb Active Member

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    hoping to get it all bolted up tomorrow and complete the hotside boost pipes, pics to follow :yahoo:
     
  8. Chris79

    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
     
  9. olethalb

    olethalb Active 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 :(
     
  10. solaris

    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.
     
  11. olethalb

    olethalb Active 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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    all done now just waiting remap
     
  12. spider74

    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.
     
  13. razza1

    razza1 Well-Known Member

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    Very jealous of you guys...looking good there!
     
  14. olethalb

    olethalb Active 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.
     
  15. spider74

    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!
     
  16. olly quattro

    olly quattro Member

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

    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!
     
  18. shropy95

    shropy95 Member

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    This is about as helpful as a thread can get ! Love it
    But I'm about to do this for myself and was wondering if anyone had a few more pictures of how they connected the charge pipe to the k04 ( an I right in thinking it has a funny machined connector ? ) and how they attached the air filter to the MAF and that's about it any help would be appreciated !! Thanks guys
     
  19. shropy95

    shropy95 Member

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    And while I'm on it what is the limit of torque for these engines (BGB) is it around 320 ft/lb? And then the rods can't hack it ? Thanks ?
     
  20. ANDYTQ

    ANDYTQ Well-Known Member

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    My BUL engine is running 383 lbft at 3700rpm and yet to be k04 custom mapped yet,i'm so glad i did the rods at the same time the ko4 was fitted,the intergrated engineering ones are nearly twice as thick.
     
  21. shropy95

    shropy95 Member

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    Hmm sounds like a must then ! How much is a set of them ? And where can I get me some :welcoming::welcoming:?
     
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  23. ANDYTQ

    ANDYTQ Well-Known Member

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    I got mine from badger 5.I cant remember the price it was part of a large list lol.
     
  24. shropy95

    shropy95 Member

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    1 last thing
    Is there an easier way of mounting the IAT sensor into my custom FMIC piping or do you have to make up a custom piece like orthalb and weld it in?
    For example is there a section of pipe I can buy to slot in Ruth some silicon joins and just bolt my IAC into it ?
    Thanks again
     
  25. shropy95

    shropy95 Member

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  26. Craig Cull

    Craig Cull Well-Known Member

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    You have to weld it in. Cost me about £20 to have none welded in. Still using it now on the big turbo build, but also had a WMI port welded into the same pipe Aswell.
     
  27. shropy95

    shropy95 Member

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    Hi again guys
    Just doing this myself now and all is going good ! Only thing I'm wondering is, do I need to recirc the air back from the diverter valve into the intake side for any reason? Or will I be okay to leave it venting to atmosphere ?
    Also if anybody has a set of injectors let me know Cheers lads !
     
  28. olethalb

    olethalb Active Member

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    Has to go back to intake, the air in the system is measured by the maf, any released to air will lead to incorrect readings / fuelling
     
  29. shropy95

    shropy95 Member

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    Brilliant, cheers mate
     

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