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Author Topic: K03-052 to K04-023 conversion  (Read 3781 times)
KasperH
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« on: July 18, 2017, 10:41:47 AM »

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 Smiley

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 Tongue
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KasperH
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« Reply #1 on: July 18, 2017, 12:07:42 PM »

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?
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SB_GLI
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« Reply #2 on: July 18, 2017, 12:45:39 PM »

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.
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KasperH
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« Reply #3 on: July 18, 2017, 01:18:40 PM »

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 Smiley
I'm not sure about KFZW/2 and KFZWOP/2?
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SB_GLI
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« Reply #4 on: July 18, 2017, 04:34:45 PM »

I would just do MAF and PID maps and modify the stock maps for everything else.
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KasperH
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« Reply #5 on: July 19, 2017, 02:06:45 PM »

Here are some shots of the parts Smiley

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  Undecided
and felt the need to cut one of the turbo coolant lines (have ordered a new one)  Angry

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.  Huh

just waiting on the coolant line and the turbo support brace
before i rip my daily driver apart and fudge it up beyond repair  Grin
« Last Edit: July 19, 2017, 02:19:51 PM by KasperH » Logged
KasperH
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« Reply #6 on: July 21, 2017, 01:04:16 PM »

Turbo support bracket straight from the mothership Smiley

and a shot of current setup.
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KasperH
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« Reply #7 on: July 21, 2017, 01:11:10 PM »

thinking about it, this topic might actually fit in better under "project cars" topic  Roll Eyes
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KasperH
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« Reply #8 on: July 23, 2017, 04:44:53 AM »

freshly painted intake Smiley
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KasperH
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« Reply #9 on: July 25, 2017, 10:40:38 AM »

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 Smiley
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vwaudiguy
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« Reply #10 on: July 25, 2017, 04:32:24 PM »

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 Smiley

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/
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"If you have a chinese turbo, that you are worried is going to blow up when you floor it, then LOL."
userpike
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« Reply #11 on: July 25, 2017, 05:49:52 PM »

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

If you go to the junkyard you may find those 90degree connectors for 2-3 bucks a piece.
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KasperH
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« Reply #12 on: July 26, 2017, 01:39:37 AM »

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 Smiley 
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KasperH
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« Reply #13 on: July 26, 2017, 05:55:30 AM »

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.  Angry
And those 2 things aren't really things I'm willing to do.
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KasperH
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« Reply #14 on: July 26, 2017, 09:03:06 AM »

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  Tongue
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