NefMoto

As title states i have chosen to use my summer vacation on converting my K03 to K04 complete with MAF, intercoolers and intake manifold.

Got new gaskets for all parts, pin bolts and coppers nuts for the exhaust manifold, extra oil and cooling fluid.

My intent for this thread is general discussion, updates and problem solving :)

So if you have any information about this topic, feel free to share, point out my mistakes and correct me if im doing somthing wrong or stupid :P

What would be easiest;
to modify my current ecu to suit the K04 setup?
Or just convert it to BAM software and replace loom with a matching BAM ECU loom?

Just take BAM PID tables and bring them into your tune as a starting point.

MAF tables, N75 tables and load tables was what I was going to start with :)
I'm not sure about KFZW/2 and KFZWOP/2?

I would just do MAF and PID maps and modify the stock maps for everything else.

Here are some shots of the parts :)

And the tool-fu of the guy who removed it wasn't very strong,
since he managed to fudge all the bolts on the cat  :-\
and felt the need to cut one of the turbo coolant lines (have ordered a new one)  >:(

And the person who previously owned the intercooler setup
apparently felt the need to have a secondary IAT sensor
JB welded to the hard boost pipe right before the TB.  ???

just waiting on the coolant line and the turbo support brace
before i rip my daily driver apart and fudge it up beyond repair  ;D

Turbo support bracket straight from the mothership :)

and a shot of current setup.

thinking about it, this topic might actually fit in better under "project cars" topic  ::)

freshly painted intake :)

I'm stuck.
The heater matrix pipes pass right in front of the turbo inlet.
I have the option to try and bend it out of the way, but risking breaking the metal pipe.
Or cut the metal pipe shorter and run a hose the rest of the way.

Any help would be greatly appreciated :)

If you have the quick release type, there's a company that made billet aluminum 90 degrees adapters that couple to the heater core.

http://www.tdnparts.com/heater-hose-connector-90/

I bought this kit because I wasn't planning on staying with the 023 forever.https://store.034motorsport.com/heater-hose-pair-mk4-1-8t-with-big-turbo.html (https://store.034motorsport.com/heater-hose-pair-mk4-1-8t-with-big-turbo.html)

If you go to the junkyard you may find those 90degree connectors for 2-3 bucks a piece.

i think i got it out of the way, i just bent it down and under the compressor housing,
now i just gotta twist the hoses a bit where they mount to the firewall
so they dont interfere with the wastegate :) 

Now the next problem is getting the oem k04 downpipe installed.
Can't really mangle it in without dropping the subframe or cutting the downpipe.  >:(
And those 2 things aren't really things I'm willing to do.

I solved by chopping the left small pipe off,
unbolting engine from all engine mounts,
leaning it forward and just cramming it in from the underside  :P

And now the cat doesn't line up with anything  >:(

And when I tried putting on the TIP I noticed that I need new heater matrix lines
and a new coolant flange on the side of the block.

I ended up getting a combi valve and tube off a BAM motor it made for alot more room for the TIP. I guess a block off plate would work but you are still running a cat right?

I found the 42 draft designs k04-023 conversion DP on Ebay for cheap(er) from a tuning company that was a few cities away from me. It was still new but was marked way down compared to what you can get them for straight from 42 draft designs. You won't have to unbolt anything with it as long as the car is on jack stands. You can turn it in from the bottom. It's a super nice piece, all their stuff is. It flows way better than the stock DP.

One thing I do recommend is you use an aftermarket TIP because the stock one will collapse at the bend in front of the turbo inlet. I've seen video of it happening. Wish I could find it to show you. This is why I spent the money on a good one instead of the china knock off. Get Samco Sport or Forge motorsport brand they are better reinforced and won't collapse.

I have deleted SAI a long time ago thankfully, it frees up alot of room.
Yeah I'm running cat right now, cause that's what I got that fits :)
Plan was to go aftermarket downpipe, in the near future.

I have been looking at different oem cats all night
And this one should fit, I just think the engine is a little crooked after loosening all the engine mounts.

I bought a aftermarket silicone TIP, cause the one I got with the kit was all old and crumbly  :P

4x12 hour days later and the first start has happened, although only downpipe was fitted.
It is alive again.

Now everything is together.
All there is left is all the ECU modifications, so it plays nice with the new setup :)

first log of it running.

and that is an impressive overshoot :P
but it pulls a lot stronger than the K03-052

some massaging with the newly developed LDRPID tool would be a good thing

an those twin sidemount intercoolers really helped on the IATs ;D

generally its a mess, but it'll get me to and from work while i fine tune the details :)
 

any opinions on copying over KFZWOP/2 and KFZW/2? :)

modify the stock maps.

didn't upgrade injectors?   They are maxed out already.

Yeah they are 06A906031BC 364cc BAM injectors.
But I kept my pig rich fuel map from the k03 where they were already at 90%DC at 6000 RPM
So naturally they wouldn't be enough for the higher and colder flow and 800 RPM more  :P

So I went with the BAM fuelling strategy, and what surprises me most is that it was all stoich
Besides lambda 0.95 from LAMFA on 99% pedal.
All other enrichment is controlled by ATR which first kicks in at 920℃

I threw a 4 bar FPR in it and went with LAMKR enrichment the other day just to be safe
Until I get some exhaust hardware related issues fixed, then I'll get it dialed in just right.
I have a trackday coming up on the 14th so I hope everything is sorted before that :)

Ev14 550/630 are cheap.

Yeah, that was my goal.
But this conversion cost a little more than I thought it would,
so I gotta save up some money again :P

This car does what a car should do,
It puts a big fat grin on my face everytime I drive it  ;D

But 1.3 bar of boost has proven to be too much for the old battered clutch.
It slips in all but 1st and 2nd. So I'm gonna dial it back to 1.1 bar, it seemed pretty happy there :)

But I was thinking of converting the ECU to a BAM one and getting he BAM loom,
so I can plug in the EGT sensor and have proper ATR.
Because I seem to remember that for the EGT sensor to work it needs SY_ATR, but I might be wrong?

Took the car to the trackday and thrashed on it for a couple of hours in 20+℃
The only big problem I had was the manifold->turbo bolts coming loose
Other than that everything held together and performed pretty good.
The S3 twin sidemount intercooler setup was okay, but heatsoaked pretty bad after a couple of laps.
So i turned it down from 1.2 bar to 1 bar flat, it was much happier there  ;D

And I think I bent something in the front suspension/steering,
and maybe damaged the front wheel bearings.
But that's what I get for running on the kerbs :P