Charlie Farley's 350BHP & beyond 2.0tfsi BUL Engine and K03/4 upgrade project, maybe just 300bhp now.

All ready have a few bits , but I think I've kinda shot myself in the foot in away.
If I was just uprating my factory fit BUL engine i'd get away with a lot less parts and expense ,but I'm not going that route.

I'm using a donor BUL lump and ecu so as to keep the original safe in case things go bang..
The seller assured me it was a good lump but I have no warranty or guarantee of its overall condition other than its a good runner, and lets face it, one would be very silly to do any sort of uprating on an unknown engine.

So that's the problem , well if you can call it a problem , more of a dilemma really.
It needs rebuilding to be safe , I knew that would be the case at the start , but how far do I take the rebuild.
From a performance and reliability point of view it would make sense and be best to do a first rate job , but with that comes the higher cost .
Do I rebuild based around a 300 -350 uprated engine or to a 400 -450 engine even if it is still geared around the 350 mark turbo size wise.

Cost is a serious factor and i'm allway mindfull of it , but, I don't want to be just throwing cash at it all sides on , well I cant as funds are limited all the same.

So that's where i'm at thus far chaps, I just need to strike that balance of cost and the end result, its my own fault really for choosing this route but i'd rather choose this over messing around with the factory lump, I like to have a working backup just in case.

I expect it will all workout in the end.:yes:
 
Last edited:
I don't blame you for all the indecisiveness. Seems to be a common thing with the A4. If it was a s3 it would be a no brainer as they can take more power. I have been here, there and everywhere with my thoughts. I've settled on the fact that I'd like a strong 350. Drop in rods and a refresh of bearings and rings etc. Primarily due to cost. And not being a science project whereby the car never sees the road again and I am confined to a diesel passat for the rest of my days dreaming about what could have been.

Anything more is a bonus.

God knows we've all been collecting parts for long enough.

Sent from my SM-G965F using Tapatalk
 
  • Like
Reactions: DieselJake
Haters gonna hate but that's why I just buy fast cars and spend a couple quid making them a couple horses faster now rather than doubling horsepower and hoping for the best (been there done that, hated the off road time and labour especially when it was me doing the work or when someone else keeps you waiting... hated it even more when all went to plan and something happened to them though!), love to see something ambitious go well but a couple horses gained and a couple pounds lost is plenty for pieces of metal that sit on my drive now.
 
  • Like
Reactions: Stanningtonglen and Charlie Farley
audi upgrades
Appreciate your views chap and Like most things in life, whatever works for the individual really.
 
I have more satisfaction making a car something it wasn't meant to be and keeping up and beating some of the bigger power cars than id ever have buying a fast car to begin with and even if i did buy a fast car to begin with i would go crazy with that as well that sit is what makes you a petrol head.

Moral of the story is its not about power your aiming for its about the journey it takes you on when achieving your goal, which from 98% of people is the goal never ends it just keeps becoming something new.

Amen
 
  • Like
Reactions: Inertiauk, Stanningtonglen, Dan_Avant and 1 other person
Ricky Burrows said:
I have more satisfaction making a car something it wasn't meant to be and keeping up and beating some of the bigger power cars than id ever have buying a fast car to begin with and even if i did buy a fast car to begin with i would go crazy with that as well that sit is what makes you a petrol head.

Moral of the story is its not about power your aiming for its about the journey it takes you on when achieving your goal, which from 98% of people is the goal never ends it just keeps becoming something new.

Amen
Click to expand...

Very true Ricky.
 
I think the 2.0t A4 platform is ripe for upgrading. The longitudinal engine and 4wd give it an edge over a lot of newer machinery!

With the quattro system it should never have left the factory with 220hp - but I understand the hierarchy politics that means the ‘lesser’ engined car should never be able to go faster than an S4 or an RS4 - which is why I believe it didn’t come as standard with the K04.

But that’s why the upgrade route is so tempting - the EA113 engine has had so so much R&D put into it and in BUL format it’s even better.

I’m with you Rob, if I didn’t use mine for work everyday I’d be looking at these options to make something you enjoy - it’s passion, and you can’t explain what drives that. We just like making our toys the best they can be.

If you can end up with a 350bhp+ motor we’ll all be jealous! Yours would be a great example, good looking, practical and fast as hell! There’s not many cars out there like that. It Takes the big balls to stump up the cash matey, good on ya!
 
  • Like
Reactions: Dan_Avant and Ricky Burrows
Bobbytea said:
I think the 2.0t A4 platform is ripe for upgrading. The longitudinal engine and 4wd give it an edge over a lot of newer machinery!

With the quattro system it should never have left the factory with 220hp - but I understand the hierarchy politics that means the ‘lesser’ engined car should never be able to go faster than an S4 or an RS4 - which is why I believe it didn’t come as standard with the K04.

But that’s why the upgrade route is so tempting - the EA113 engine has had so so much R&D put into it and in BUL format it’s even better.

I’m with you Rob, if I didn’t use mine for work everyday I’d be looking at these options to make something you enjoy - it’s passion, and you can’t explain what drives that. We just like making our toys the best they can be.

If you can end up with a 350bhp+ motor we’ll all be jealous! Yours would be a great example, good looking, practical and fast as hell! There’s not many cars out there like that. It Takes the big balls to stump up the cash matey, good on ya!
Click to expand...
100% true
 
The whole reason I chose the A4 b7 was for the tfsi engine with permanent 4 wheel drive. It’s also more practical than an S3, which you need when you have kids and dogs etc.

It really is a good base to build on. Not without its faults, as were all aware!!!
 
So what is the difference between a hybrid K03 and a Hybrid K04 , or just one of the same really?

In my head a hybrid K04 is a KO4 core with a machined K03 housing .
 
Last edited:
Just Rob. said:
So what is the difference between a hybrid K03 and a Hybrid K04 , or just one of the same really?

In my head a hybrid K04 is a KO4 core with a machined K03 housing .
Click to expand...
You got it Rob just using the ko4 internals probably wont see you much past 350-400 though i could be wrong
 
A hybrid k03 is usually something along the lines of a k04 internals in a k03 body

Then a hybrid k04 is say k06 internals inside a k04 body.

what makes it a hybrid is usually a turbo that’s the same standard physical size but has bigger internals than the standard turbo making it able to produce more power.

a hybrid k04 would no doubt still need adjustments as they never came for a longitudinal engine but they’d produce more power than a standard k04
 
I see , so with the right build / parts and decent remap using a Hybrid K03 I could prob get 400 tops then.
 
  • Like
Reactions: Ricky Burrows
I see things starting to come together now, :icon thumright: just need to see a man about a turbo this weekend:yahoo:, I'm getting all excited now.:salute:
 
  • Like
Reactions: Ricky Burrows
Another day and a bit further with initial ground work on parts.
I'm going with uprated pistons:

Mahle PowerPak Piston Set for 2.0T FSI/Golf R/S3 Engines
MAH-FSI-197799948

rod's:
IE Forged Connecting Rods VW & Audi 144X20 | Fits 1.8T 20V & 2.0T FSI
IERHVA1-RD


and bearings:

Mahle Motorsport/Vandervell Race Rod Bearing Set for VW/Audi 4 Cylinder
MAH-VC1027


but not touching the head except to give it a good decoke etc then use the s3 injectors etc.

just need to find a decent reliable source to order from now.

Onwards again..:icon thumright:
 
  • Like
Reactions: Sidrick and Bobbytea
Just out of interest,

How much do you think to total of this K04 build would be? I’m assuming while you’ve got the engine build going on you’ll add new ancillaries? Engine mounts? Cooling upgrades?

Are you tempted with a solid flywheel or are you sticking with the Dual mass?

I think the bottom end upgrades pistons and rods/ bearings is a brilliant way to go, that allows for head work later on - especially when you get addicted to increasing the power and start chasing 1/4 mile times haha.

The FMIC you’ve got, Will it support the boost the KO4 will supply?

Ah man, I wish I could do this project - I’m so excited for you!
 
Total cost, i'll let you know when its all done as I just don't know now, hopefully a bit lower now.
Yep replacing all the normal bits as to be expected ,so hoping to end up with a nice powerplant.
I think I will stick with a good dual mass flywheel unless something happens to change my mind.

Now the FMIC, I already have a JHM unit but it when I bought it a while back the plan was just stage 2 at most , and I have not even unboxed it yet, I've emailed JHM and asked their views on it's suitability for what I have planned , no reply as yet so will have to sit on the fence for now, worse case i'll sell it on and get something else if needbe.
Upload 2020 1 16 20 1 3
 
Just Rob. said:
Total cost, i'll let you know when its all done as I just don't know now, hopefully a bit lower now.
Yep replacing all the normal bits as to be expected ,so hoping to end up with a nice powerplant.
I think I will stick with a good dual mass flywheel unless something happens to change my mind.

Now the FMIC, I already have a JHM unit but it when I bought it a while back the plan was just stage 2 at most , and I have not even unboxed it yet, I've emailed JHM and asked their views on it's suitability for what I have planned , no reply as yet so will have to sit on the fence for now, worse case i'll sell it on and get something else if needbe.
View attachment 196433
Click to expand...
Looks a bit small your probably need to go with the airtec i got Rob its twice the size and they say at stage 2 its not required but will be a nice addition so im sure it will be more rhan fine for what your going for, also its the width you got to take into count as some are really narrow.
 
It is quite thick though ricky , the core is 3.5 inches thick, maybe it gains more by being thicker than taller /thinner.
 
Not sure if you have ordered bearings yet but you might want to hang on until youve had the crank checked over, theres always potential for needing over/under sized ones. It only takes one journal to be a bit on the limit
 
  • Like
Reactions: Charlie Farley
Not ordered them as yet, I wanted to find a source that I can order as many part as possible.
Good suggestion on the crank front chap, i'm going to strip the whole engine down anyway so that will get on my list to double check.:icon thumright:
 
I bought the donor engine blind from a seller in germany and no not off ebay .
I was given the guys details via a friend in Belgium, anyway the seller seems genuine and it was a good price , with a service history etc, but that means nothing really as we all know from experience.
I've organised a courier that wasn't asking an arm , leg and half my internals deliver it, hoping to see it latter end of next week all being well.

Just have to keep ticking the boxes off now.
 
Thanks chap, workshop tools and special tools are one thing I have a very good collection of, probably way to many.
They mount up over the years from one job to another, still keep buying more though as many engines need more and more specific tools.
 
I think that ribe is the only odd ball with one other exception being the arp bolts on new ie conrods, after them its the usual torx/star/hex mainly.
If you put the rings on pistons yourself i highly recommend getting an expander, much easier than without.
 
  • Like
Reactions: Charlie Farley
Ricky Burrows said:
Looks a bit small your probably need to go with the airtec i got Rob its twice the size and they say at stage 2 its not required but will be a nice addition so im sure it will be more rhan fine for what your going for, also its the width you got to take into count as some are really narrow.
Click to expand...

I've had a very helpful few replies from JHM this evening, they do a taller one , very similar to the airtech ones .
They have advised the one I have will be ideal for my specific application and have had very good result with the same setup.
So i'll carry on with using the one I have.
 
  • Like
Reactions: Bobbytea and Sidrick
audi upgrades
Just Rob. said:
I've had a very helpful few replies from JHM this evening, they do a taller one , very similar to the airtech ones .
They have advised the one I have will be ideal for my specific application and have had very good result with the same setup.
So i'll carry on with using the one I have.
Click to expand...

Good to know! I like the compact height of the one you’ve got. Does it fit snug under the impact bar?
 
Ricky Burrows said:
I have more satisfaction making a car something it wasn't meant to be and keeping up and beating some of the bigger power cars than id ever have buying a fast car to begin with and even if i did buy a fast car to begin with i would go crazy with that as well that sit is what makes you a petrol head.

Moral of the story is its not about power your aiming for its about the journey it takes you on when achieving your goal, which from 98% of people is the goal never ends it just keeps becoming something new.

Amen
Click to expand...
Ricky I Couldn't agree more its all about making it your own putting your own mark on it, if its giving it more power or putting bigger wheels on so be it. I have done this with every car I have owned . LONG LIVE MODIFYING :yahoo::racer:
 
  • Like
Reactions: Ricky Burrows
Another day and a bit more progress.
Now have the turbo bits and getting the machining sorted this week hopefully.:icon thumright:
Right next job.:yes:
 
  • Like
Reactions: Bobbytea and Ricky Burrows
A bit further , getting the K03 housing shipped down to be machined tomorrow, hopefully back by Friday and then I can rebuild the new hybrid unit.
In the meantime i'm going to get the manifold all prepped and make sure the wastegate face is spanking clean and flat , don't want any boost leaks there, also fabricate a new wastegate actuator mounting bracket.
Its nice to mess around with bit's , very satisfying.:yes:

Turboko3 4
 
Nice. You’ll have some good gains from that.

I’ve finally got everything on my car, engine wise and it’s ready for a remap. Got a quote for a full custom map -£650 :flushed:
 
Dan_Avant said:
Nice. You’ll have some good gains from that.

I’ve finally got everything on my car, engine wise and it’s ready for a remap. Got a quote for a full custom map -£650 :flushed:
Click to expand...
Bleedy hell wheres that from? Bevo are good down south if your that way think theres is £300, rtech if your fwd are £375+vat, performance remap in south west are very decent also at £300 all in, i wouldn't pay more that £400 for a top quality custom map mate.
 
That was from devil developments mate. On the other side of the country from me as well. Probably cost me £70 each way in fuel with the way I accelerate to 70 :whistle2:
 
I got a quote from TSR Performance in Bridgewater. They’re a Revo dealer and they quote me £545 for a stage 3 map
 
Dan_Avant said:
That was from devil developments mate. On the other side of the country from me as well. Probably cost me £70 each way in fuel with the way I accelerate to 70 :whistle2:
Click to expand...
Yeah i heard devil developments are really good i guess if your ko4 the price goes up for longer tuning possibly? A lot if money but at least it will be in good hands i guess.
 
You must log in or register to reply here.

Similar threads

Charlie Farley
B7 avant 350BHP 2.0tfsi project.
Replies
8
Views
5K
i3oricua
i3oricua
Charlie Farley
  • Sticky
Charlie Farley's 2.0tfsi Full PCV Delete project, and why you need to do it too.
Replies
362
Views
177K
Charlie Farley
Charlie Farley
mdm83
2.0tfsi BUL engine advice
Replies
32
Views
33K
imotepify
imotepify
Charlie Farley
Just for all you "BUL" engine code owners......and myself included.
Replies
17
Views
13K
ttelracs
T
wanderinwurzel
BUL engine oil consumption & cam follower upgrade?
Replies
6
Views
6K
BennyG_UK
BennyG_UK
Top
Back