Club G40 Forum

Technical => Turbochargers => Topic started by: electricpanda on January 24, 2012, 08:27:40 am

Title: Another Turbo Advice thread!...
Post by: electricpanda on January 24, 2012, 08:27:40 am
I know there's loads and I've looked through most of them..

Just getting together parts to do a k03 swap on my g.

Can anyone let me know if I've missed anything off my part list or if anyone has any advice from there experience doing this.

So far I have (fitted)

250cc injectors
264/268 cam (hope this will suffice)
Up rated spark plugs and Magnecor leads
Seat 1.8t FMIC

In the process of ordering/sat in the garage..
Ko3 turbo
G40-K03 Manifold and Downpipe
G40 exhaust gasket
K03 to manifold gasket
K03 to downpipe gasket
1.8T oil lines
All hoses to mate up to FMIC and T into water lines
Forge Actuator.

Thanks for any help.
Title: Re: Another Turbo Advice thread!...
Post by: Etches on January 24, 2012, 09:04:32 am
You still need a base turbo map, and factor in a mapping session with ppp. I'm at the same stage with my turbo build apart from i need everything before i take mine off the road!

Aswell sorry you need a 6psi boost switch you will find the thread link from CHEYS thread, also a boost bleed valve which is also on chris's thread, a brazed sump fitting is needed for the oil return from the turbo
Title: Re: Another Turbo Advice thread!...
Post by: hayesey on January 24, 2012, 09:16:31 am
you need a dump valve too!
Title: Re: Another Turbo Advice thread!...
Post by: electricpanda on January 24, 2012, 09:29:30 am
Thanks lads,

Yeah mines still on the road, sourcing everything first, I'll have a loo for that thread.

I have a dump valve too forgot to say.

Will I need a turbo chip then a custom map or can I just use the chip I have and get that altered?

Cheers
Title: Re: Another Turbo Advice thread!...
Post by: hayesey on January 24, 2012, 10:16:17 am
you need a chip to suit a turbo setup.  Then that generally gets altered to suit your exact specification - that's a custom map.

how much boost do you plan on running?  if it's much more than a bar then you'd need a larger map sensor to go in the ecu too.
Title: Re: Another Turbo Advice thread!...
Post by: electricpanda on January 24, 2012, 10:45:23 am
I was hoping about 1-1.5 don't wanna over stress it but want a decent gain.

Guess I'll need that too then!
Title: Re: Another Turbo Advice thread!...
Post by: hayesey on January 24, 2012, 11:45:47 am
erm, that's not very specific, there's a hell of a difference between 1 bar and 1.5 bar.  You need to decide and spec the engine to suit.  if you want 1.5 bar then you will need to change the map sensor, standard one is good for up to 1 bar.
Title: Re: Another Turbo Advice thread!...
Post by: electricpanda on January 24, 2012, 12:45:54 pm
I know haha. I haven't really decided. It's a daily so don't want to make it unreliable by pushing it too far. I did want more towards 1.5 bar if I'm honest so will have to change it. I want 180ish Bhp if I can
Title: Re: Another Turbo Advice thread!...
Post by: electricpanda on January 24, 2012, 07:52:00 pm
By the way, doesn't the boost bleed valve control the boost pressure? Won't the forge actuator do that?

Also do I need to modify the throttle body?
Title: Re: Another Turbo Advice thread!...
Post by: Andy on January 24, 2012, 07:57:05 pm
1 bar = 175bhp or thereabouts on one of these engines. So that means standard MAP sensor can be retained.

I'd make sure you're 100% sure of the health of the rest of your setup before planning the turbo conversion though.
Title: Re: Another Turbo Advice thread!...
Post by: electricpanda on January 24, 2012, 08:23:49 pm
Thanks Andy, The engine as a whole in great condition, no funny noises, fsh and only done 60 odd thousand.

Just that fuelling problem, I still can't get to the bottom of it. My fuel pump was very loud on the way home from work tonight and makes a strange chirping noise constantly so going to check fuel pressure on Saturday.

Thanks for the help.
Title: Re: Another Turbo Advice thread!...
Post by: dub-disaster on January 24, 2012, 10:33:50 pm
if your going to be turboing it and winding the boost up to 1.5 bar it could be worth changing both fuel pumps anyway i did mine as if your 19-20 year old pump fails whilst your on full boost your engine wont thank you for it. also if you get a forge actuator you dont need a bleed valve.
Title: Re: Another Turbo Advice thread!...
Post by: Etches on January 25, 2012, 10:56:53 am
What pumps are you using then mate?
Title: Re: Another Turbo Advice thread!...
Post by: dub-disaster on January 25, 2012, 11:48:48 am
im using an uprated inline with a the same pressure rating as standard but a higher flow, and i replaced the intank pump with a genuine vw one
Title: Re: Another Turbo Advice thread!...
Post by: hayesey on January 25, 2012, 01:10:02 pm
the standard pump will be fine in terms of flow rate as long as you're not going for over 200bhp but if your pump is old and making funny noises then it'd be well worth buying a new one.  when they fail they tend to wreck the whole engine.
Title: Re: Another Turbo Advice thread!...
Post by: Etches on January 25, 2012, 06:59:07 pm
Well mines probably getting around 171k old now, do Gsf or Vw still stock these or is there a good alternative?
Title: Re: Another Turbo Advice thread!...
Post by: dub-disaster on January 25, 2012, 08:10:27 pm
when i checked the gsf inline ones where 4 times the price of the aftermarket one i bought so i went for the uprated one there are two good one mentioned herehttp://www.polog40.co.uk/forum/index.php/topic,6403.0.html (http://www.polog40.co.uk/forum/index.php/topic,6403.0.html) i went for the cheaper of the two although i wish id gone for the walbro now as i cant seem to find any flow information for higher pressures than 3bar for the sytec one i think its rated to 135 lph which is plenty but its rated at 3 bar and i intend on running 1.5bar boost so would like to know the flow at 4.5 bar although i would imagine it will still exeed what i require.
 
Did a few quick calcs and i rekon for 250bhp you need 1.4 L/minute which is 84 Lph so they sytec one should give plenty of head room and is rated upto 8.5 bar although it would flow a hell of alot less up there!

the walbro one is well more than youll need think it flows about 180Lph at 4.5 bar

You can pick up that sytec one for about £45 if you have a look around try searching for opt017, as for lift pump i bought it from vw think it was around £60-70 but it was worth it because fitment is exactly the same so i could replace just the pump not the entire fuel sender as gsf would only sell it as an entire assembly

Hope this helps and by no means take my calculations as fact just information i used when buying my fuel pumps all of the internet so take with a pinch of salt