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

[Charlie Farley]

Well chaps it seem's like I've been full circle now as I embark on a project that I originally setout to do some time ago but decided against.

It's the ever popular K04 and engine upgrade project on the 2.0tfsi engine in the B7 variants.
I've been umming and arrrring over the last few years on the project , should I , shouldn't I and is it worth the agro and cost.
The Mr sensible in me says don't go there it will only end in tears , which it may well do...lol, but the Mr Risky in me say's go on do it , you know you want too...
So That's what i'm going to do, throw caution to the wind and do it.....and may god have mercy on my soul.


Right this is my project plan and like all plans may well change along the way so go with me chaps.

I've sourced a donor BUL engine minus clutch and gearbox, but otherwise complete , its done similar miles as my factory fit BUL of around 80K so not too bad.
I would never trust an unknown engine unless it came from myself so i'll need to strip it down to see what the format is and go from there.

Plan is to get safe and reliable 350BHP out if it, which should be very doable without taking out a second mortgage...lol.

Sort the inlets out etc for carbon , fit the S3 injectors , HPFP, K03 /4 hybrid etc , new clutch .
Probably fit new rods too .
Whilst in there check out the oil pump and suction pipe situation along with fitting a new camchain/tensioner and variator.
I'll move over the 034 HFC and large downpipe from my exisisting engine to the project engine , but source a second ECU which will be remapped to suit.
I have a very good FMIC already to fit so that's sorted.

That's the basic stuff and then refit to the old bus , this way my original engine is safe along with the ecu and other bits , its almost like an insurance policy should things go tits up..lol
Weather I continue to use the pedal box , well that will have to be assessed based on the final effects of the upgrade.

Lots to do then and plenty of updates and pics to come.

I still think i'm mad but hey , one has to live on the wild side sometimes.


Rob

 

[Jon13s]

Sounds good Rob and been a long time coming. I'll be sat here waiting for updates. I have the parts necessary to do this to my DTM minus the injectors; however I currently lack the time and capacity to gain knowledge necessary to tackle it myself.



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[Charlie Farley]

I do like a challenge , but i'd only tackle this project by using suitable donor engine, I just cant see the point in wrecking a perfectly good and running engine.
I'm sure there will issues along the way , well i'm expecting them but like all things in life , its a learning curve and mistakes will happen and i'll just have to learn from them, hopefully not too many though.

Hopefully with the help from all you other guys things should work out fine.

The bonus factor with using a donor engine for me are.
I don't loose the use of the old bus, I get to keep the original engine etc as backup , and if the project takes a bit longer its not a problem, almost a win win situation .

rob

 

[Sygh2k]

if your planning on doing rods, maybe worth looking at rod/piston combo. i recently replaced my rods after spun shell syndrome, and i mite have been better that route as opposed to having my pistons recoated+ringed(+required honing). alot will depend on the bores tho.

 

[Charlie Farley]

if your planning on doing rods, maybe worth looking at rod/piston combo. i recently replaced my rods after spun shell syndrome, and i mite have been better that route as opposed to having my pistons recoated+ringed(+required honing). alot will depend on the bores tho.

Cheers chap, will keep that in mind.
Until I get the lump stripped down and assess things more I wont be 100% on what need's doing from a remedial point of view.
I was told it was in perfect order but one cant work on just a sellers word.
rob

 

[Charlie Farley]

if your planning on doing rods, maybe worth looking at rod/piston combo. i recently replaced my rods after spun shell syndrome, and i mite have been better that route as opposed to having my pistons recoated+ringed(+required honing). alot will depend on the bores tho.

What state of tune is your engine running at present.

 

[Sygh2k]

ive just about done 1k miles(3oil changes) on the rebuild, running revo2+, got to adjust my meth system in summer. no idea what the power is but being 2wd it shreads tyres.

i plumped for the ecs ra4 clutch flywheel combo and also the vis freewheel oil pump pulley at same time, so far so good, definetly revs free'r but not pushed it yet.

 

[Charlie Farley]

ive just about done 1k miles(3oil changes) on the rebuild, running revo2+, got to adjust my meth system in summer. no idea what the power is but being 2wd it shreads tyres.

i plumped for the ecs ra4 clutch flywheel combo and also the vis freewheel oil pump pulley at same time, so far so good, definetly revs free'r but not pushed it yet.

Yep, I can fully understand the tyre shreading..that must get a tad costly.
That's another reason why I felt doing the upgrade to my quattro bus was such a good base to work with , fully utilize all the power .

 

[Charlie Farley]

I'm doing a shopping list on what I need over the next few days, I have some of the upgrade parts but the tip of a much bigger iceberg..lol

Cost wise, I have no idea frankly on what it will work out at but have set my budget for a maximum of £4k and that's its, no going over that figure.
I think that will pretty well cover things , if not some adjustments to the project may come into effect..lol
I have no intentions of getting into a " Crossrail " situation where the budget just get bigger and bigger with no sign of success or completion.

 

[Sygh2k]

i never planned going so far but once you start its a bit like pringles
tyres generally a pair of fronts every 12-15months but i do get 15k miles.
when its dry tho its outstanding

 

[Charlie Farley]

Oh yes, I know all about pringles chap, I have a tube in front of me now , and sheer will power is not working either..

 

[Sygh2k]

I'm doing a shopping list on what I need over the next few days, I have some of the upgrade parts but the tip of a much bigger iceberg..lol

Cost wise, I have no idea frankly on what it will work out at but have set my budget for a maximum of £4k and that's its, no going over that figure.
I think that will pretty well cover things , if not some adjustments to the project may come into effect..lol
I have no intentions of getting into a " Crossrail " situation where the budget just get bigger and bigger with no sign of success or completion.

you should manage under 4k easily, i reckon ive spent around 2.5k doing all the work myself.

i found cartech one and eurocar good for sundries etc then the likes of aks tune, progressive and psi for the specialist bits

 

[Charlie Farley]

you should manage under 4k easily, i reckon ive spent around 2.5k doing all the work myself.

i found cartech one and eurocar good for sundries etc then the likes of aks tune, progressive and psi for the specialist bits

The handy to know chap.

 

[Charlie Farley]

Having looked back I think it was 5 years ago when I first started on this upgrade subject, that's not bad going then as its only taken me that long to finally bite the bullet and do it., long overdue then

 

[THQuattro]

Hi Mate
I just replied to your RS4 thread and now i found this thread ha ha , this sound exciting mate i hope it works out for you.

 

[Charlie Farley]

Hi Mate
I just replied to your RS4 thread and now i found this thread ha ha , this sound exciting mate i hope it works out for you.

I have aborted finding an RS4 B7 Avant for the time being chap, plenty around but just cant find that illusive one I want , its out there but just not for sale yet.

I'll save the pennies for now, but also spend some on the old bus to make up for things.

 

[Charlie Farley]

almost forgot , I will of course be installing my newest PCV delete setup with this project, a very worthy cause indeedy.

 

[Bobbytea]

Just keep in mind with added power comes added torque, hows your ‘box? A rebuilt box can be costly. Just something to keep an eye on.

Have you looked at diff upgrades to send the horses rearward in a 60:40 split similar to an RS4?


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[Charlie Farley]

I have not had any issues with gear box or diffs thus far, fully intended to give them all a proper oil change when I do the swap.
Thanks for heads up , allways nice to get as much feedback as possible.

 

[Ricky Burrows]

Looking forward to seeing how this goes Rob, i think 350hp is a good number to aim for you do lose a lot through the drivetrain being 4wd but should be enough to keep up with the rs4 you was looking at i honestly don’t think your buy the rs4 after the ko4 upgrade, as for drivetrain/clutch issues with torque the tuner will just adjust the mapping and cap torque if it slips so shouldn't be a problem overall, just upgrade the clutch and adjust the map at a later date if it does slip or cause issues.

sygh2k id love to know a bit more on your car when your run in, ill be taking mine to stage 2 with rtech by summer latest and I'm fwd so id be interested to see how yours is compared to stock

 

[WOMBLERULZ]

going to keep an eye on this

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[WOMBLERULZ]

already split the k03 to put s3 k04 chra in .

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[Sygh2k]

check you manifold for cracks around the wastegate

mine was toasted at 170k

 

[Charlie Farley]

Looking forward to seeing how this goes Rob, i think 350hp is a good number to aim for you do lose a lot through the drivetrain being 4wd but should be enough to keep up with the rs4 you was looking at i honestly don’t think your buy the rs4 after the ko4 upgrade, as for drivetrain/clutch issues with torque the tuner will just adjust the mapping and cap torque if it slips so shouldn't be a problem overall, just upgrade the clutch and adjust the map at a later date if it does slip or cause issues.

sygh2k id love to know a bit more on your car when your run in, ill be taking mine to stage 2 with rtech by summer latest and I'm fwd so id be interested to see how yours is compared to stock

I love the rs4 v8 lump though, a 2.0 tuned turbo at around 350bhp still doesn't sound or drive like a well sorted N/A V8 , two very different animals really.
But since Rs4 are off my wish list for now i'll be happy to tinker with the old bus and get some extra ponies out of it,also something to do in my spare time...

 

[Charlie Farley]

After a chat with friend I may have to just bite the bullet and go for as much as possible really , well within the realm of sensibility that is.
Given i'm using a donor engine there seems to be no reason other than from a wallet point of view why it shouldn't be tuned for a tad more.
It could be seen as a missed opportunity otherwise , so that's the modified way forward , and a few more bits to aquire now.

The old bus owes me nothing now so onwards I go .
450 has been suggested so i'll aim for that and see how things go, I did say this project may change along the way chaps..lol

 

[Bobbytea]

Holy cow batman! 450bhp would be awesome!!!

 

[Charlie Farley]

I had to Edit the thread title now aswell, "350bhp & beyond" .

 

[Ricky Burrows]

Do you have to forge anything at 450 Rob? Or is it just the case if bigger turbo and supporting mods?

 

[Charlie Farley]

Not 100% sure on what is needed at this stage, but i'm going to do a belt and braces engine rebuild with whatever is required .
Valves , pistons ,rod 's etc , silly to skimp and then blow it up later .

now where's that lottery ticket...lol

 

[Charlie Farley]

Going to drop Edgar a pm as he's running around 400+ mark to get some feedback on things.

 

[Sygh2k]

rob, have a read through here if you havent already, lots of usefull info,

https://performancebyie.com/blogs/ie-auto-blog/definitive-guide-building-2-0t-fsi-bottom-end

 

[Charlie Farley]

So then, thus far I have the following parts .
Donor BUL engine with inlet manifold , ecu , etc is organised , just need to get it shipped.
S3 injectors
HPFP core
FMIC and parts

parts that will carry over from my exisiting lump will be .
034 HFC
quad exhaust tips & large bore downpipe .( will need a new 3" centre system now)

Parts I need , well that's evolving daily as the new plan will dictate parts .
Clutch & flywheel
mid section Exhaust and back boxes .
All the required parts to rebuild the donor engine to the desired output .

plus anything else which will be a few more bits.

then a decent remap.

A big question that has now arisen is the turbo, I was going the hybrid route but may need to do some research now into what the best option will be.

I'll keep you updated as I progress further, I'm still in the planning and part aquasition stage so will be a little while before spanners start moving and thrown around..lol

 

[Charlie Farley]

rob, have a read through here if you havent already, lots of usefull info,

https://performancebyie.com/blogs/ie-auto-blog/definitive-guide-building-2-0t-fsi-bottom-end

Not seen that , will have read now over a cuppa and biscuits..

 

[Charlie Farley]

rob, have a read through here if you havent already, lots of usefull info,

https://performancebyie.com/blogs/ie-auto-blog/definitive-guide-building-2-0t-fsi-bottom-end

That's an excellent article chap, it has clarified a fair few questions in one swoop.
Interestingly in does also answer a few age old questions that have been asked about the BUL code engine , they do seem to clarify that certain engines , I would assume the BUL is one does have differing parts to the other 2.0tfsi lumps used in the b7.


So a few bits to get now then inc drop in rods and pistons etc .

 

[Charlie Farley]

As my old bus is not really a daily driver in the normal sense these days, more of an occasional non work daily what I have planned is just personal usage.
I'm not some power crazed owner chasing bonkers bhp, just a avid b7 owner and doing these upgrades is more for my own tinkering and enjoyment purposes .
Still useable for daily driving if needbe and taking out the woofers..lol
A good way to get something a little bit different and special, some extra ponies without buying another bus for the same purpose.
To look at just another A4 B7 really but with a bit more of a beast under the bonnet, ideal for a weekend trackday blat in avant format.

Anyway, that's my plan .

 

[Sidrick]

Looking forward to the build, Rob.

If I was getting silly I'd be looking at maybe changing power plant. The old S2 motors make good power. A B7 with that 5-pot sound would be something else.

 

[Charlie Farley]

Just aswell I did the 18z caliper upgrade a few years back , may well need it now.. , thinking S4 rears to even things out a bit.

 

[Ricky Burrows]

Looking forward to the build, Rob.

If I was getting silly I'd be looking at maybe changing power plant. The old S2 motors make good power. A B7 with that 5-pot sound would be something else.

Is that the same engine thats in the b5? 2.7 twin turbo (if I remember correct?) if so that engine is an animal easy to get big power and sound ace.

 

[Sidrick]

Is that the same engine thats in the b5? 2.7 twin turbo (if I remember correct?) if so that engine is an animal easy to get big power and sound ace.

No buddy, that motor is a V6. Does sound great though. The S2 was inline 5, 2.2 turbo.

 

[Charlie Farley]

Looking forward to the build, Rob.

If I was getting silly I'd be looking at maybe changing power plant. The old S2 motors make good power. A B7 with that 5-pot sound would be something else.

I would think that sort of transplant would be great but would it be doable.