Another Turbo Advice thread!...

[electricpanda]

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.

[Etches]

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

[hayesey]

you need a dump valve too!

[electricpanda]

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

[hayesey]

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.

[electricpanda]

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!

[hayesey]

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.

[electricpanda]

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

[electricpanda]

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?

[Andy]

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.

[electricpanda]

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.

[dub-disaster]

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.

[Etches]

What pumps are you using then mate?

[dub-disaster]

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

[hayesey]

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.