Ok, I went and did it... K04
06-22-2000, 02:24 PM
#1
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Ok, I went and did it... K04
Just got off the phone with Todd at AWE and I'm sending him a check out in the morning for one of those snazzy TT K04's with fuel a fuel pressure regulator. Turbo is $1595, fuel pressure regulator is $60.
I'll order a new 225 exhaust manifold from Clair tomorrow morning as well and when they all show up send them to Extrude Hone in Paramount CA and have both turbo and exhaust manifold extrude honed as a mated unit and gasket matched for higher flow rates and 3-400rpm faster spool-times.
Don't expect immediate feedback on this as it could still be months out with all the work I'm going to do or having done. Could be as late as Oct/Nov before all my ducks are in a row on this, tho I'd like a late Aug/early Sept install on it all. Objectively, somewhere in between.
I will do it all at the same time when all "prep" work is done.
When I'm done this could be the first 300HP (at the wheels) TT in the U.S.
Conversion will consist of the following:
1. Custom 6.75"(H) x 32"(W) x 4.5"(depth) Spearco intercooler mounted in lower center grill and associated ductwork/plumbing.
2. 225 intake manifold extrude-honed and gasket matched and flow bench tested. Balanced flow rates in all intake runners (already done).
3. Cylinder head ported inlets and gasket matched to intake manifold.
4. K04 turbo and new 225 exhaust manifold extrude honed and gasket matched to each other.
5. 3" stainless steel downpipe & high flow catalytic converter (will have to be custom-made).
6. Custom Garrett Stage 4 chip which larger intercooler will allow.
7. Convert existing intercooler to oil cooler.
In trying to be objective this matematically adds up to a potential 350HP (crank) TT with plus/minus 300BHP at the wheels.
Where's Mtn Man Dan live anyway? Yoo-hoo, oh Mr Dan... wait up for me please... I have something for you.
I'll order a new 225 exhaust manifold from Clair tomorrow morning as well and when they all show up send them to Extrude Hone in Paramount CA and have both turbo and exhaust manifold extrude honed as a mated unit and gasket matched for higher flow rates and 3-400rpm faster spool-times.
Don't expect immediate feedback on this as it could still be months out with all the work I'm going to do or having done. Could be as late as Oct/Nov before all my ducks are in a row on this, tho I'd like a late Aug/early Sept install on it all. Objectively, somewhere in between.
I will do it all at the same time when all "prep" work is done.
When I'm done this could be the first 300HP (at the wheels) TT in the U.S.
Conversion will consist of the following:
1. Custom 6.75"(H) x 32"(W) x 4.5"(depth) Spearco intercooler mounted in lower center grill and associated ductwork/plumbing.
2. 225 intake manifold extrude-honed and gasket matched and flow bench tested. Balanced flow rates in all intake runners (already done).
3. Cylinder head ported inlets and gasket matched to intake manifold.
4. K04 turbo and new 225 exhaust manifold extrude honed and gasket matched to each other.
5. 3" stainless steel downpipe & high flow catalytic converter (will have to be custom-made).
6. Custom Garrett Stage 4 chip which larger intercooler will allow.
7. Convert existing intercooler to oil cooler.
In trying to be objective this matematically adds up to a potential 350HP (crank) TT with plus/minus 300BHP at the wheels.
Where's Mtn Man Dan live anyway? Yoo-hoo, oh Mr Dan... wait up for me please... I have something for you.
06-22-2000, 03:29 PM
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More info
Hi i am also interested on making these changes to may car please send me the URL if they have if not the phone, also will be glad if you answer me when you have done the changes
06-22-2000, 05:46 PM
#6
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Why is the Turbo so expensive?
If the turbo is $1595 and the kit is $2200, what is the $605 being spent on? Is that the exhaust they installed on the test TT?
Mance, what did Todd tell you?
Mance, what did Todd tell you?
06-22-2000, 06:08 PM
#7
There is more than just a turbo in the "kit", and more than a new turbo is required to get 256hp!
From PES's website
referring to the A4/Passat 1.8T setup)
TRIPLE-K K-04URBOCHARGER
PERFORMANCE FUEL INJECTORS
PROPRIETARY GIAC/PES CHIP
NEW GASKETS
NEW HIGH TEMP HARDWARE
NEW SPARK PLUGS
PES INSTALLATION MANUAL
PES LIMITED WARRANTY
Could be an additional item or two for our setup.
I called and talked to Gary @ PES for over 30min today. He said the labor should be $600-$800 and about 10-11 hours. Also Larry, the 10-11 hours is for everything, sure you could do the turbo yourself in 1-2 hours(but I highly doubt it) but then you have all the other stuff to do....I have a feeling this is WAY more involved than you think it is, and you won't achieve the performance unless everything is upgraded per their design.
Gary said that my "custom" borla should be acceptable to mate with the K04 kit. The stock TT exhaust would need to be replaced, and I "think" any aftermarket cat back exhaust would work(not remus, muffler only) but it sounded like he favored either the Supersprint, or my custom borla application for max flow. He did say the supersprint is even quieter than the normal borla! That's REALLY quiet!
I am going to have this done as soon as I have the available funding, putting everything else on hold
<p>-Jenner
'00 TTqX Garrett Stage II, Borla, H&R Sport Springs, Stable Energies Shoulder Harness Bar, Deist 6 point Race Harnesses, LLTEK rear light covers and floor mats, V1, Custom stereo, 3M rear tint, etc. BIRA in progress</a>
referring to the A4/Passat 1.8T setup)TRIPLE-K K-04URBOCHARGER
PERFORMANCE FUEL INJECTORS
PROPRIETARY GIAC/PES CHIP
NEW GASKETS
NEW HIGH TEMP HARDWARE
NEW SPARK PLUGS
PES INSTALLATION MANUAL
PES LIMITED WARRANTY
Could be an additional item or two for our setup.
I called and talked to Gary @ PES for over 30min today. He said the labor should be $600-$800 and about 10-11 hours. Also Larry, the 10-11 hours is for everything, sure you could do the turbo yourself in 1-2 hours(but I highly doubt it) but then you have all the other stuff to do....I have a feeling this is WAY more involved than you think it is, and you won't achieve the performance unless everything is upgraded per their design.
Gary said that my "custom" borla should be acceptable to mate with the K04 kit. The stock TT exhaust would need to be replaced, and I "think" any aftermarket cat back exhaust would work(not remus, muffler only) but it sounded like he favored either the Supersprint, or my custom borla application for max flow. He did say the supersprint is even quieter than the normal borla! That's REALLY quiet!
I am going to have this done as soon as I have the available funding, putting everything else on hold
<p>-Jenner'00 TTqX Garrett Stage II, Borla, H&R Sport Springs, Stable Energies Shoulder Harness Bar, Deist 6 point Race Harnesses, LLTEK rear light covers and floor mats, V1, Custom stereo, 3M rear tint, etc. BIRA in progress</a>
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06-22-2000, 06:44 PM
#8
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Jenner, I don't think that much is involved in this kit for the TT.
The injectors are larger than the A4 injectors. Mance has already talked to Todd and it does not sound like he is doing anything other than the turbo.
The turbo swap is about a 2-3 hour job. It is actually not too difficult to swap out. I have done harder things in the past, like building an entire race car from the ground up in a garage!
What is so different about the Supersprint exhaust from the Borla, or the LLTek or some of the others?
Does this mean the wheels are on hold?
The turbo swap is about a 2-3 hour job. It is actually not too difficult to swap out. I have done harder things in the past, like building an entire race car from the ground up in a garage!
What is so different about the Supersprint exhaust from the Borla, or the LLTek or some of the others?
Does this mean the wheels are on hold?
06-22-2000, 06:45 PM
#9
AudiWorld Super User
Thread Starter
the 1.8T setup has a LOT to catch up to TT specs before it'll compare...
The TT doesnt require new injectors as these injectors we have now should flow enough fuel to handle almost 400HP. TT injectors as-is are MONSTER injectors.
Secondly there's nothing "proprietary" about the chip according to Garrett. No one has an "exclusive" on TT/K04/Garrett chips cept Garrett. Gareret said its a $20 upgrade... thats it.
Gaskets are cheap from Clair or even the local Audi parts counter. And you gotta do those any time you break apart a sealed mating surface. No biggie.
New spark plugs... maybe... maybe not. With the new intercooler I'm going to use, prolly not. But worse-case thats an easy $10/10 min job.
I dont have a clue what "new high-temp hardware" is but I cant see it whatever it is. All heat shielding is in place. And if more is required it'll be apparent rather quickly with a good mechanical sense and a visual inspection.
I dont think this is a fun conversion but I dont think its 10-11 hours either. I had my turbo out on the workbench and back in in under 3 hours. There is not one single bolt or procedural difference in substituting a K04 and a K03 in that regard.
And I think Larry can do it... and you too for that matter. In less than half of the claimed time even being really really cautious/careful. There just really isnt anything hard or difficult about this. Yes its a "PIA" and some of the bits/pieces are hard to get at/to. And most of it has to be done under the car. But it aint 10-11 hours.
I dont think this is "involved at all. maybe if you're not very mechanical or lacking hand/eye skills or tools and a hydraulic lift its a LOT more difficult. But it isnt a very daunting task overall.
FPR is the only thing you didnt mention... 20 mins tops.
This is not THAT hard. But you easterners have PES/AWE to do the install. "Necessity" being the mother of invention I can get real inventive to staive a 2K mile drive to pay someone $2-3 large to do something I've done dozens of times before.
And ya know what? I'd never done one either till I did my first one. No one was born knowing how to do this or much else really. Your $... your call.
Secondly there's nothing "proprietary" about the chip according to Garrett. No one has an "exclusive" on TT/K04/Garrett chips cept Garrett. Gareret said its a $20 upgrade... thats it.
Gaskets are cheap from Clair or even the local Audi parts counter. And you gotta do those any time you break apart a sealed mating surface. No biggie.
New spark plugs... maybe... maybe not. With the new intercooler I'm going to use, prolly not. But worse-case thats an easy $10/10 min job.
I dont have a clue what "new high-temp hardware" is but I cant see it whatever it is. All heat shielding is in place. And if more is required it'll be apparent rather quickly with a good mechanical sense and a visual inspection.
I dont think this is a fun conversion but I dont think its 10-11 hours either. I had my turbo out on the workbench and back in in under 3 hours. There is not one single bolt or procedural difference in substituting a K04 and a K03 in that regard.
And I think Larry can do it... and you too for that matter. In less than half of the claimed time even being really really cautious/careful. There just really isnt anything hard or difficult about this. Yes its a "PIA" and some of the bits/pieces are hard to get at/to. And most of it has to be done under the car. But it aint 10-11 hours.
I dont think this is "involved at all. maybe if you're not very mechanical or lacking hand/eye skills or tools and a hydraulic lift its a LOT more difficult. But it isnt a very daunting task overall.
FPR is the only thing you didnt mention... 20 mins tops.
This is not THAT hard. But you easterners have PES/AWE to do the install. "Necessity" being the mother of invention I can get real inventive to staive a 2K mile drive to pay someone $2-3 large to do something I've done dozens of times before.
And ya know what? I'd never done one either till I did my first one. No one was born knowing how to do this or much else really. Your $... your call.
06-22-2000, 07:52 PM
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U r the MAN ! U beat me in doing the turbo upgrades first. Dont forget AP brakes like LarryTT.
<p>180FWD/17"BBS RX2/S-02PP/PipercrossFilter/PIAA/Wetterauer/Remus/GReddy Turbo gauge/Forge Motorsport dump valve/NGK Iridium/Abt steel brakelines/H&R coilovers/Postert rear spoiler
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