Finished K04 install

**Killerteve** · 05-10-2008 12:02 AM

Finished installing my k04-15 with an issue I need help with. I had to use the stock hardware on the 034 manifold and two nuts didn't fit. The stock nuts are huge and wouldn't clear the large manifold. All others but these two on the top inner two wouldn't fit. Should I worry?

The afe intake silicon TIP to turbo piece is ripped about 1/4 the way around where the clamp has sliced it, the gasket for the dv to tip has also ripped which cause the connection to blow out on a test drive. both of these are causing huge leak in the tip so I don't feel safe driving in the current state. I am hoping to scrap the whole thing tomorrow if I can find a apr/forge/neuspeed tip in the area and will use the remnants to fab an intake using the afe's cone filter and maf connection.

On the test drive I was surprise by the boost. It was easily spiking to 24 psi and holding at 22. I wasn't expecting that with my revo stage 2. What vac/boost number should I be seeing? The power was there but I was afraid to go wot knowing not everything was perfect.

**diagnosticator** · 05-10-2008 04:28 AM

Don't run the engine with rips in the intake hose. The ripped areas won't leak boosted pressure intake air, but will allow unmetered air into the engine, causing lean fuel/air ratios, and dirt will get sucked into the engine also. Are you running K-04 specific ECU tuning or K-03 files? If still K-03, that is the reason the boost pressure is too high. Install stainless flange nuts where necessary. Don't drive the car until after installing the missing manifold nuts.

**ehfour** · 05-10-2008 08:33 AM

Aside from your issues,

How long did it take you to do?

**dewey527** · 05-10-2008 11:07 AM

be careful with the afe intake and the gromets. it was a tight fit on the last L inlet and the inside part of the gromet came off and went thru the turbo

good job on the install. i did not do it since the car was already in the shop for something else.

**AudiA4Turbo22** · 05-10-2008 11:27 AM

can't wait for dyno results!

**Killerteve** · 05-10-2008 12:06 PM

I'm running revo stg 2 with no fmic yet, so the fueling should be ok. I'm not driving it until the tip is fixed. I also thought of a way to keep the 02 sensor installed but that would require it to be touching the exhaust mani. I know it get hot just from being in the test pipe and around the turbo hotside/mani area so would that be ok? Does that sensor need to be installed since it's blocked by the revo software anyway?

**AudiA4Turbo22** · 05-10-2008 12:08 PM

^^i think that sensor is necessary and all the software does is change it's reading!

**Killerteve** · 05-10-2008 04:21 PM

So I fixed all the leaks in the tip and start it up and it's kinda running like shit. I noticed some white smoke coming from the exhaust as well as some drops of liquid a clearish color and I couldn't tell if it was coolant. It seem to be running fine as I took it out for the next test drive. A short way into the drive (1.5 min, no boosting, no speed over 20mph) the car starts surging pretty bad and the check engine light starts flashing. The check engine light goes off a few seconds later but the car still is still surging. I think it might be that there is a leak in the hose from the n75 to the turbo(not the wastegate actuator). I limped the car another few blocks back to my house where it started sputtering so I shut it off. I checked all the fluid levels and connections and everything is fine with no leaks. What could be the problem?

**Killerteve** · 05-10-2008 05:16 PM

Update: 02 sensor is reconnected, turbo inlet leaks fixed. No noticeable leaks under the car.

Car starts and sputters, feels like it will die if I don't give it gas. Now I'm thinking bad time for the coilpacks to die? I have a set of ngk bk7re's I could put in too, though the shop replaced my other sparks with the stock plugs saying they are better for the car. Also ever since I first started it with the new turbo it make a strange deep whirring sound when I press the gas. At first it only did it in reverse and not it is doing it when I rev from idle to 3k in neutral. I need help please!!!