Author Topic: From Standard to K03 to K04 + Rebuild  (Read 9948 times)

Offline AdzCM

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Re: From Standard to K03 to K04 + Rebuild
« Reply #15 on: March 12, 2014, 09:18:09 pm »
Are you still running a standard MAP sensor? If so, that'll be what's holding you back if you're aiming for well over 15psi.
Yeah, I know about the MAP sensor cheers. My mapper advised me to wait until I fitted the forged pistons and rebuilt the engine before upping the boost/fuel, which was good advice as I don't think the engine was anywhere near healthy enough to hack it.
Fair enough. 15psi on a healthy bottom end is usually enough for 175bhp in my experience, so may well be that your old motor was a bit tired.

Yeah, I reckon it was. It was breathing really heavily and had more blow-by than I would have liked. Should be interesting to see how it goes with a 1341 :)

« Last Edit: March 12, 2014, 10:27:48 pm by AdzCM »

Offline AdzCM

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Re: From Standard to K03 to K04 + Rebuild
« Reply #16 on: March 23, 2014, 03:38:35 pm »
With nothing else to do 'engine wise' I thought id go ahead and sort out the K04.

It had a few problems that needed to be sorted in order for it to fit and work.

First off, its the K04-023 from an Audi TT/S3 and has a hold in the exhaust housing for an exhaust gas temperature sensor [EGT] so I had to get this blocked up. I had thought about maybe even fitting an EGT sensor but figured it would be easier/cheaper to just block it up.

That was until after research I found the hole to require an M11 x 1mm pitch blanking bolt which were impossible to find.

So I bought an M12 x 1.25 brass blanking bolt/washer and an M12 x 1.25 top and bottom tap.



I thought the tap might completely eat the existing threads and leave a smooth hole, but it didn't and worked a treat. The brass blanking bolt tightened right in :)



Then the forge actuator came in the post:



Fitted it to the K04 and the housing was just not going to fit with the radiator in its way so had to sort this.



I thought about just switching the plate [that holds the actuator] the other way round, but it just wouldn't work because of the shape of the plate. So thought about using the standard actuators plate.



Its only after I realised I could have just ground the other side of the plate where the actuator is crimped round the centre hole. Butchering it seemed to work just as well:



This allowed me to bolt the actuator to the other side of the plate:



Then allowed me to rotate the turbo housing to a much better angle for it all to fit:





Simple enough fix, but well worth it. Would be a massive pain if I couldn't get the housing rotated down more.

Does anyone else think there's not a lot of thread left on the actuator rod for pre-load? Where it sits now, the waste gate is closed tight, but just. If I had a red 17.5 - 20psi spring fitted, how much more thread [if any] would I need to put approximately 23psi on it? Might have to space the actuator away from the mounting bracket a bit...
« Last Edit: March 23, 2014, 03:42:00 pm by AdzCM »

Offline z3i

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Re: From Standard to K03 to K04 + Rebuild
« Reply #17 on: March 23, 2014, 06:24:28 pm »
Absolutely loving this!! Has anyone fitted a k04 before?

Offline z3i

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Re: From Standard to K03 to K04 + Rebuild
« Reply #18 on: March 23, 2014, 07:21:11 pm »
any ideas what the characteristics and driveability of the 04 would be like? it looks alot bigger than an ko3

Offline AdzCM

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Re: From Standard to K03 to K04 + Rebuild
« Reply #19 on: March 24, 2014, 01:34:14 pm »
Absolutely loving this!! Has anyone fitted a k04 before?

Cheers buddy. I have no idea if anyone has fitted a K04-023 but I think a few have fitted a K04-015. A guy off here dan1300r has the K04-015 and it sounds like a really good setup. I might be the first to let you all know whether going K04 is a good idea or not haha.

Offline physicsfool

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Re: From Standard to K03 to K04 + Rebuild
« Reply #20 on: March 26, 2014, 02:10:49 pm »
What do the last 3 numbers refer to? (-023 and -015)
Ta

Offline AdzCM

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Re: From Standard to K03 to K04 + Rebuild
« Reply #21 on: March 26, 2014, 08:27:04 pm »
015 means the exhaust housing is from a K03 I believe. The 023 has a bigger exhaust housing and has a hole for an EGT sensor. Your trusty friend google could probably tell you more ;)

Adrian

Offline Andy

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Re: From Standard to K03 to K04 + Rebuild
« Reply #22 on: March 26, 2014, 09:45:32 pm »
The K03 or K04 part just tells you which family the turbocharger is from, the numbers which follow indicate which variant it is (i.e. what size turbine and compressor wheels and what size and type of housings etc.)

Turbine and compressor housings and wheels can differ significantly even on turbos from the same family.

Offline AdzCM

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Re: From Standard to K03 to K04 + Rebuild
« Reply #23 on: April 27, 2014, 06:04:54 pm »
Still waiting on the BVH :( so still doing anything and everything I can to keep me busy.

Got the gearbox back with Quaife diff fitted. Took ages with some heavy duty cleaner and then a wire brush drill attachment to prepare it for paint:



Then painted it:



Then painted the engine mount bracket and 5th gear case and finished it off:




Offline AdzCM

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Re: From Standard to K03 to K04 + Rebuild
« Reply #24 on: April 27, 2014, 06:14:57 pm »
Loved the wheels I had on the car last year but always wanted a set of banded steels so got some :)






Offline AdzCM

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Re: From Standard to K03 to K04 + Rebuild
« Reply #25 on: April 27, 2014, 06:17:52 pm »
Painted them Ford Nimbus Grey because its awesome against capri green IMO:







Offline AdzCM

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Re: From Standard to K03 to K04 + Rebuild
« Reply #26 on: April 27, 2014, 06:18:57 pm »
Took off all the old oil saturated, crusty loom tape and redid the whole loom with new stuff:


Offline AdzCM

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Re: From Standard to K03 to K04 + Rebuild
« Reply #27 on: April 27, 2014, 06:20:06 pm »
Refitted the front mount after doing a little bit of cutting/grinding/painting to make it all fit. Nothing serious:


Offline AdzCM

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Re: From Standard to K03 to K04 + Rebuild
« Reply #28 on: April 27, 2014, 06:26:41 pm »
Thinking about getting a full respray at some point so I just did a rough job of spraying the bay. Might aswell wen the engine was out:




Offline AdzCM

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Re: From Standard to K03 to K04 + Rebuild
« Reply #29 on: April 27, 2014, 06:30:47 pm »
I had fitted this to run with the K03 but didn't have a build thread back then. The location seems to be good enough as oil temperature was never a problem. Always sat around 60-80 if I can remember and when it got quite hot from spirited driving, it cooled quite quickly.