S3 turbo on A4 2.0 Tfsi DIY:ish

[AudiCoupe]

Okey so I have fitted an Audi S3 turbo (K04) to my A4 and will try to do a DIY on this as I know there are many questions regarding this and not a lot answers.
Sadly I have not taken enough pictures of the install process so I'll just describe it the best I can.

I will not describe how to remove and install the turbo because there are already DIY:s for that.

List of parts needed:
- S3 turbo
- S3 injectors
- custom downpipe
- custom turbo outlet (picture 1 number 1)
- HPFP upgrade
- Oil lines (picture 1 number 2)
- Vacumpipe turbo -> engine (picture 1 number 3)
- Dumpvalve relocation (picture 1 number 4)
- Misc Nuts and bolts
- Misc gaskets

Picture 1 from Turbozentrum's upgrade kit.



CUSTOM DP:
The exhaust flange on the S3 turbo will not fit the A4 downpipe because the bolts are further apart on the S3 turbo.
There are S3 flanges for sale at ebay but I did not use one of those. I bought a standard testpipe for an A4 and a magnaflow 200 cell cat. I cut away the corners on the flange where the holes are and welded in new metal and drilled new holes.

Here I have testfited the testpipe with the modified flange.


The magnaflow cat that will be welded in



MODIFICATIONS TO THE TURBO:
Because the turbo outlet flange is bigger on the S3 turbo the flange will hit a engine mount.
To deal with this you need to cut of a bit of extra metal on the turbo flange. In my case this was enough but there is a possibility you would have to modify the engine mount as well...
Here you can se that I have trimmed down one of the corners of the turbo flange:



CUSTOM TURBO OUTLET:
This is at the welder at the moment but it will be similar to the one in picture 1 number 1.
This outletpipe will connect to the stock rubberhose.


OIL AND WATER PIPES:
Stock water pipes do fit quite easily.
Stock oil pipes can be bent to fit. This is what I did but I believe that the S3 oil pipes should be a even better fit.


VACUME PIPE (PICTURE 1 NUMBER 3):
The two holes for the bolts are wider apart on the A4 so either you can drill a new hole and make it fit or you can go with a pipe from a S3.


DUMPEVALVE RELOCATION:
The S3 turbo do not have an internal dumpvalve so you will need to move this. There are some relocation-kits available. I have made a outlet for the dumpvalve in the turbo outlet pipe (pic 1 number 1)

Some pictures of the install:





Injector tool I made from a standard slidehammer:





I know that this is not a great DIY but it's a start and I will try to anwser all your questions...


I will be getting my car mapped / chiped with the new hardware 24:e june so I'm hoping to make about 320-330 hp.

[Operator]

Will be sure to stay tuned for your updates!

[rvca3112]

is it possible to remove the turbo without taking off the HFC? i mean like doing the whole removal of the cat and then removing the turbo or can you just take the turbo out while leaving the cat in place?

[AudiCoupe]

is it possible to remove the turbo without taking off the HFC? i mean like doing the whole removal of the cat and then removing the turbo or can you just take the turbo out while leaving the cat in place?

Yes you can remove the turbo without removing the downpipe / cat.

[b7kevin]

Sick can you provide a picture of where you shaved down the turbo and motor mount clearance?

[Pr0n]

Who will be doing your ECU tune?

[b7kevin]

http://cbtuning.net/store/products.php?3

Guys heres a kit for 2095 shipped with everything... This work for us?

[ringofsteel]

http://cbtuning.net/store/products.php?3

Guys heres a kit for 2095 shipped with everything... This work for us?

Will this kit work with a APR Map for their Stage III?

[jayphil82]

Will this kit work with a APR Map for their Stage III?

This will work with APR K04 software but not with the big turbo software. Anyway APR do not sell thier Stage IIII software separately.

http://cbtuning.net/store/products.php?3

Guys heres a kit for 2095 shipped with everything... This work for us?

Yes but you will still have to do the modification explained by the OP.

is it possible to remove the turbo without taking off the HFC? i mean like doing the whole removal of the cat and then removing the turbo or can you just take the turbo out while leaving the cat in place?

Why would you do that, you need to cut / modifiy you HFC to bolt to the S3 turbo anyway and it would be easier to do so the HFC out of the car.

- - - -

AudiCoupe thanks for the write-up. Like asked above a picture of the trim to be done on the turbo would be appreciated!

[b7kevin]

question, rather than modify the turbo can you modify the k03's compressor shell and bolt that to the turbo itself?

It looks like apr started with a s3 turbo and then slapped the k03's 'face' on.

[tecnica]

Will this kit work with a APR Map for their Stage III?

This will work with APR K04 software but not with the big turbo software. Anyway APR do not sell thier Stage IIII software separately.

Check out 'Stage 2+'

[martin0079]

question, rather than modify the turbo can you modify the k03's compressor shell and bolt that to the turbo itself?

It looks like apr started with a s3 turbo and then slapped the k03's 'face' on.

It is possible but is it worth the cost or the effort. NO. You would to have a machine shop directly match the two commpressor housin making sure that everything matches to maintain the boost curve and final boost pressure of the turbo costing prolly lots of money. If the housing are identical then no big deal but most likely they are not. Cheaper to just get an outlet pipe

[rvca3112]

This will work with APR K04 software but not with the big turbo software. Anyway APR do not sell thier Stage IIII software separately.



Yes but you will still have to do the modification explained by the OP.



Why would you do that, you need to cut / modifiy you HFC to bolt to the S3 turbo anyway and it would be easier to do so the HFC out of the car.

- - - -

AudiCoupe thanks for the write-up. Like asked above a picture of the trim to be done on the turbo would be appreciated!

personal knowledge.

[Satummoo]

I got really excited to find the kit you posted

http://translate.google.com/translat...e%2Fa-27999%2F

But then...

2249 euros = 3225.7407 US dollars

:-( :-( :-(

I still think it's ridiculous that there is no cheap turbo upgrade option without paying 4,500$ for APR's option

[AudiCoupe]

Sick can you provide a picture of where you shaved down the turbo and motor mount clearance?

I updated my first thread so there is now a picture of where I trimmed the edge of the turbo.

[AudiCoupe]

Who will be doing your ECU tune?

The tune will be done by a well know european tuner.

[AudiCoupe]

http://cbtuning.net/store/products.php?3

Guys heres a kit for 2095 shipped with everything... This work for us?

Yes I can not see why this would not fit but you will still need to do the custom work to get everything to fit.

[Charles]

I know back when I did a K04 swap in my B5 Passat, the rebuilder assembled the compressor housing at the wrong angle. I was able to loosen the compressor housing, where it attached to the center cartridge housing and slightly rotate the comp housing until it was at the right angle. Would something like that be possible here to address the compressor outlet pipe not clearing the motor mount?

[AudiCoupe]

I know back when I did a K04 swap in my B5 Passat, the rebuilder assembled the compressor housing at the wrong angle. I was able to loosen the compressor housing, where it attached to the center cartridge housing and slightly rotate the comp housing until it was at the right angle. Would something like that be possible here to address the compressor outlet pipe not clearing the motor mount?

No that is not possible because the exhaust housing and exhaust manifold is all one piece.

[Charles]

I know that... :)

If you look at your pics, the turbo has 3 pieces, at least from what I can tell. An exhaust/manifold housing, the center section which holds the compressor/exhaust turbine cartridge, bearings and oil/water connections, and the compressor housing. The exhaust side, as well as the compressor side, are attached to the center cartridge section. Typically, you can loosen the compressor housing and rotate it, which will have no effect on the turbine/manifold.

Looking at this pic:
https://pgperformance.com/images/P/8.jpg

It seems that the exhaust side is attached to the center section via a compression clamp and the compressor is attached with bolts. Can you not loosen that compression clamp and rotate the center section and compressor housing just a tad?

[b7kevin]

Is there a retailer for the turbo outlet pipe? I've been scouring the net to no avail.

[AudiCoupe]

Is there a retailer for the turbo outlet pipe? I've been scouring the net to no avail.

This is the closest I've got in my search. It's the complete package...
http://www.turbozentrum.de/turbos-co...grade/a-27999/

[AudiCoupe]

Got some work done today so here is an update on my build progress:
- Removed the intake and injectors (this is a real pain in the behind to remove but not impossible)
- Upgraded my hpfp pump with an autotech kit
- Waiting for gaskets for injectors and intake so these will be installed in the begginning of newt week.
- Got my custom made turbo outlet pipe back from the welder.

And here are some pics:

Turbo outlet:


Intake and injectors:


Some carbon buildup:


Great looking camfollower with 62k miles on it (I think)


Upgraded hpfp:

[Doctor]

Do yourself and your engine a favor and change the cam follower every 7000-10000 kms.

[tecnica]

nice, following this

[AudiCoupe]

Do yourself and your engine a favor and change the cam follower every 7000-10000 kms.

Yes I'll do that especially now when I have a upgraded pump... Reason it have not been changed before is that I recently bought it.

[Doctor]

Yeap I am with you. Good Luck with the build man

[DioTrix]

GOOD LUCK MAN !!! More fotos PLZ =)!

[AudiCoupe]

An other update:
I have now got the car mapped and this thing is FUN =)
I blew of the turbo outlet hose after I flashed the first tune so thats always a good sign. I'm now using double clamps on that hose and I can say that this turbo upgrade is perfect for those who want a stock looking motor with stock driveability but som more power.
We had to try 6 versions of the tune to get it to perfect. We had some retarding issues because the MAP sensor only gos to 2.6bar and the boost spike goes way over that. But we have now that under control and the car now delivers the power smoothly.
Now producing ~330Hp and 450Nm

[leetcao]

Awesome build.

Could you tell me roughly how much you've spent so far to get it to where it is now? I would really like to have around 280-300whp with daily drivability so going the S3 route seems interesting to me.

[AudiCoupe]

Awesome build.

Could you tell me roughly how much you've spent so far to get it to where it is now? I would really like to have around 280-300whp with daily drivability so going the S3 route seems interesting to me.

Yes I can =)
- Used S3 turbo with 15k km: 505€
- Used S3 Injectors with 15k km: 224€
- HPFP upgrade: 300€
- Chip: 300€
- Magnaflow cat + testpipe: 221€
- Gaskets and misc. items: 100€
- Aluminium pipes and bends: 80€
- Welding work (DP + turbo outletpipe): 100€

SUM: 1830€ -> 2580 $

[AudiCoupe]

Some time since I last posted an update on this so here's what I've been up to.
The car did not deliver the power smoothly and I got faultcodes on the low pressure fuel system and on the rear O2. I've now changed the O2 and almost all of the components on the low pressure side of the fuel system. After changing the fuelpump in the tank I got rid of the last fault code and the car is now delivering the power just about as smooth as stock.

Here is a shaky 3:d gear pull:
http://youtu.be/BartuYThXiw

[rar12hoven]

dear Audicoupe,....
I have ordered this kit also, today i started with the supply, but i don't understand the following:

The S3 turbo do not have an internal dumpvalve so you will need to move this. There are some relocation-kits available. I have made a outlet for the dumpvalve in the turbo outlet pipe (pic 1 number 1)

Can you drop some pictures how you have supply it on your car ????
Thanks in advance,
remon

[AudiCoupe]

dear Audicoupe,....
I have ordered this kit also, today i started with the supply, but i don't understand the following:

The S3 turbo do not have an internal dumpvalve so you will need to move this. There are some relocation-kits available. I have made a outlet for the dumpvalve in the turbo outlet pipe (pic 1 number 1)

Can you drop some pictures how you have supply it on your car ????
Thanks in advance,
remon

On the A4 turbo the dumpvalve is mounted directly on the turbo itself but on the S3 turbo there is no "hole" to mont the dumpvalve in. This means that you need to mount the dumpevalve some where on the outlet piping from the turbo.
You can see in the picture above of the turbo outlet pipe that I've welded in a smaller pipe for the dumpvalve.

[rar12hoven]

thats wat i understand,
but it must also be connected to the inlet also, so i was wondering if you have a picture of it ?

[ShadowGLI]

Interesting, especially as this is like 1/2 the cost of most of the "premade" kids.

cool thread

[Martin_1990]

Hey did you use a front mounted intercooler also what kind of mpg does it return