DIY S3 K04 Kit (under development)

[jayphil82]

Hi guys,

Someone made an attempt not a while ago to gather information about building our own K04 kit and the thread got nowhere. Since I did some homework I want to share where I am and anyone having more information can share it.

** Disclaimer** I have not tried the kit yet my self**

Please only post informative stuff in the thread


Injectors / install kit and Intake Manifold Gasket
TTS / S3 Injectors-**************06F906036F-****4X-********62,50-*****250,00 $**-Ebay.co.uk
Injector Install Kit***************06D998907******4X********12,79** *****51,16 $***OEM (ECS, Genuinevwaudiparts…)
Gasket - Intake Manifold**********06F129717D*****1X*********21,31* ******21,31 $***OEM (ECS, Genuinevwaudiparts…)

Turbo Installation Kit
K04 S3 Turbo-******************06F145702C-****1X-******1 135,00 $***1 135,00 $
Exhaust Manifold Gasket-**********06F253039F-****1X-*******7,00 $*********7,00 $******-OEM
Breather Tube Gasket ************06F 145 757 F-**1X-********2,14 $********2,14 $******--OEM (ECS, Genuinevwaudiparts…)
Stud-Priced Each (10x28) *********N0445203-******4X-*********1,67-********2,14 $******-OEM (ECS, Genuinevwaudiparts…)
Head Bolt-*********************N91084801-****4X-*********0,47-********1,88 $******-OEM (ECS, Genuinevwaudiparts…)
Turbo Oil Line Sealing Washer ******N 013 851 4-****4X-*********0,95-********3,80 $******-OEM (ECS, Genuinevwaudiparts…)
M8 - Self Locking Nut ************N 908 946 01-***5X-*********0,47-********2,35 $******-OEM (ECS, Genuinevwaudiparts…)
HOSE CLAMP *******************N 909 265 01-***2X-*********3,27********6,54 $******-OEM (ECS, Genuinevwaudiparts…)
HOSE CLAMP *******************N 907 816 01-***2X-*********4,96********9,92 $******-OEM (ECS, Genuinevwaudiparts…)
Oil Return Gasket ****************06F145757H-****1X-********1,68-********1,68 $******-OEM (ECS, Genuinevwaudiparts…)
Turbo Oil Line Gasket-Lower********058145757A *****1X-********4,71-********4,71 $******-OEM (ECS, Genuinevwaudiparts…)


Flange that will need to be welded to your Testpipe or HFC
Turbo Downpipe Flange-**********ATP-FLS-071-*****1X-*******24,00-*******24,00 $******-ATP
OE Turbo To DP Gasket ***********1K0 253 115 K-**-1X-********11,95*******11,95 $******-OEM (ECS, Genuinevwaudiparts…)

DV Relocation
For the DV relocation I am trying to reproduce what Stasis did in their kit. They relocated the DV just before the Intercooled air enter the engine and the overflow is rejected in the turbo inlet pipe.
1. Use the Silicone "BOB" T Pipe as the coupler after the intercooler pipe.
2. To the 1" T connector you will connect the DV Relocation flange with the DV mounted to the flange facing the silicone coupler.
3. To the other 1" outlet of the DV relocation flange you will connect your 5" long 1" hose and this hose.
4. You will need to connect the 5" long hose to the turbo inlet pipe (pipe between airbox and turbo).
5. Uses the connectors and extension wires harness to plug back the DV.

DV Relocation Flange-***********06F 145 751*****1X-********69,00 $******69,00 $******OEM (06F 145 751) (ATP flange will not work)
1" hose for DV rel. (per ft)********ATP-SIL-026-*****5X-*********8,50-*******42,50 $******--ATP
Silicone "BOV" T pipe***************************1X*********19,99*** ****19,99$ ******Silicone Intakes
1" Hose Clamp-****************CLC-CLA-015 *****4X-*********0,85-*******3,40 $******--ATP
WIRE SET (dv relocation)*********000 979 133 A-****2X-********9,22-*******18,44 $******--OEM (ECS, Genuinevwaudiparts…)
WIRES (dv relocation-***********000 979 134 A-****2X-*********6,14*******12,28 $******--OEM (ECS, Genuinevwaudiparts…)
HOUSING to DV Connector**********1J0 973 722-****1X-*********15,36******15,36 $******--OEM (ECS, Genuinevwaudiparts…)
HOUSING to harness Connector******8D0 973 822*****1X-*********5,13-*******5,13 $******--OEM (ECS, Genuinevwaudiparts…)


Price of all parts currently listed 1700$-1800$

What is currently missing to have a complete kit

• Custom Intercooler piping (turbo outlet pipe) since the compress outlet is not in the same angle than the K03
• Custom work (welding of the flange, drilling, grinding) all this should be pretty minimal
• Turbo inlet pipe with bung for the DV relocation hose
• Tune (Upgrade your APR tune to K04 tune for 299$ / Unitronic tune for 700$)

1.) The turbo exhaust flange on a S3 and A4 are completely different. So, your A4 downpipe will NOT bolt up to this turbo and a custom downpipe will have to be made that incorporates a S3 (or GTI) flange.

2.) The manifold will not seat properly to the head unless the appropriate ear of the exhaust flange is trimmed and a new hole drilled (it will hit the motor mount).

3.) The compressor outlet and inlet of the turbo are in different locations than an A4. You would need custom hoses to make this work.

4.) A4s have a DV that's incorporated into the turbo where as the S3 has no provisions for this. So, your custom compressor outlet hose will also have to have a bung for a DV.

[ryandoka10]

great write up man.

[Coderedpl]

Seems cheaper than the off the shelf kits out there but now I'm thinking that it could potentially be more expensive due to the labor that needs to be done to get it properly setup?

[jayphil82]

Seems cheaper than the off the shelf kits out there but now I'm thinking that it could potentially be more expensive due to the labor that needs to be done to get it properly setup?

That is what I am trying to find out. This is what is currently missing:

1. Extra price to fit the new S3 flange to your testpipe / HFC (50-100$ of time since I included the flange in the first post)

2. Trimming and drilling a new hole in the Exhaust Maniflod (not clear for me what is really involved and how big the trimming is but should not be more than 2h of machining)

3. Hardware and time for custom IC hoses (we all know that IC piping and silicone hose a easy to find to make a custom setup).

4. I am not sure yet were and how to plug the DV relocation kit but with 1" T fitting, hose/clamps I already included in the price and custom IC pipe with 1" adaptor we can manage something. I will contact ATP so see if the have IC pipe with 1" fitting for the DV relocation.

No 1. to 4. should not cost that much....

5. Do not forget the HPFP (Autotech, KMD AWE, APR)300-600$ for rebuilt.

[AWDTURBO]

I have looked into this because we have done this exactly to my buddies GLI. His car was so easy to do, now our cars it would just be smarter to go get a kit already UNLESS you know ow to custom fab stuff yourself. I dont have those tools but i do have tools to bolt on an kit i buy so i guess i would save on the labor ..

[jayphil82]

I have looked into this because we have done this exactly to my buddies GLI. His car was so easy to do, now our cars it would just be smarter to go get a kit already UNLESS you know ow to custom fab stuff yourself. I dont have those tools but i do have tools to bolt on an kit i buy so i guess i would save on the labor ..

I agree, this is not for everyone since custom work is involved but I am pretty sure that when we will have this well documented the custom work involved will not be that bad and that part alone could be done by a shop.

I do not plan to install the turbo kit my-self and I have a good mechanic this is willing to to this kind of work so I am a good candidate.

Also I am currently Stage 2+ so I already have
APR HPFP (550$ or 850 if I include the new oem pump I purchased from genuinevwaudiparts.com)
034 HFC (not included in other shop kit)
APR Tune (550$)
S3 Injectors (250$ not installed).

Basically for me the hardware missing and APR tune upgrade will cost me ruffly 1750$ all included.
If I add all the part previously purchased to compare to other kit it totals
2550$ without HPFP / 3100$ HPFP rebuilted / 3400$ including new OEM HPFP and APR rebuilt

Turbo kit takes around 12h to install by a shop and probably 2-4 more for a "custom" like mine.

We are still close to 1000$ less than tuner's kit without considering the fact that if I buy the APR kit I will not get any credit for my Stage 2+ tune I already have (which brings the difference to 1550$ )...

In conclusion, for people that already have HPFP and APR flash it makes a lot of sense!

Let's not start a price war / comparasion with tuner's kit. People will be able to better choose the route they prefer after seeing the information in this thread.

If anyone has information about what is involved by using a OEM S3 KO4 in a B7 platform please share

[jayphil82]

I just added the injectors install kit which bring up the price by about 50$

[baldy]

Subscribed!...

I'm in a similar situation... Parts (turbo, injectors, etc.) can be sourced relatively cheap from europe, and I already have Uni Stage 2 (cheap to upgrade software to K04, therefore I don't want APR software)..

Too bad APR won't sell their kit without software..

[DioTrix]

http://www.atpturbo.com/mm5/merchant...egory_Code=FSI
good news from ATP, but I have auto transmission and don"t now how it feel with this modification.

[Baruch]

No dice on their conversion kit? - ATP

[jayphil82]

http://www.atpturbo.com/mm5/merchant...egory_Code=FSI
good news from ATP, but I have auto transmission and don"t now how it feel with this modification.

Auto transmisson will not like the GT28RS nore your rods, spool to fast and to big torque spikes. I you were MT I would suggest you to consider this
http://www.atpturbo.com/mm5/merchant...Category_Code= or the GT30 kit...

But for me it is not an option because I would cost me twice the price of the K04 kit in the end with the higher price of the tune, need to replace the rods ....

My plan is K04 and Water Meth kit + APR 100 oct file which is rated to 355chp / 368 ctq... That will be enough power for me + I will be able to run more stock like power during winter(APR Stock mode) to put less stress on my car.

- - - - - -

I have a question regarding the S3 K04 turbo vs K03. I heard that the K04 had a twin scroll manifold.

First is it true?
And what about the K03, is it twin scroll?

[VegasAIV]

^^if its really only 350hp then the auto will be able to handle it.

[DioTrix]

Auto transmisson will not like the GT28RS nore your rods, spool to fast and to big torque spikes. I you were MT I would suggest you to consider this
http://www.atpturbo.com/mm5/merchant...Category_Code= or the GT30 kit...

But for me it is not an option because I would cost me twice the price of the K04 kit in the end with the higher price of the tune, need to replace the rods ....

My plan is K04 and Water Meth kit + APR 100 oct file which is rated to 355chp / 368 ctq... That will be enough power for me + I will be able to run more stock like power during winter(APR Stock mode) to put less stress on my car.

- - - - - -

I have a question regarding the S3 K04 turbo vs K03. I heard that the K04 had a twin scroll manifold.

First is it true?
And what about the K03, is it twin scroll?

I want K04 too, because it easier for me and enough power for me and my tiptronic=)

Interesting, REVO has file for K04 longitudinal?

k04 and k03 have not twin scroll (very small turbos)

this is twin skroll turbo


and this image shows how it works

[psiaddict85]

http://www.atpturbo.com/mm5/merchant...egory_Code=FSI
good news from ATP, but I have auto transmission and don"t now how it feel with this modification.

Very interesting! But is there a tune out there?

[jayphil82]

I want K04 too, because it easier for me and enough power for me and my tiptronic=)

Interesting, REVO has file for K04 longitudinal?

k04 and k03 have not twin scroll (very small turbos)

You do not need big turbo to benefit from twin scroll technology. New Hyundai 2.0t Sonata uses twin scroll, GM 2.0T ecotec uses a Twin-scroll K04 turbo also.

Stasis K04 kit for B7 A4 uses twin scroll. I first thought it was the S3 turbo but seems not because it is from Mahle...

"STaSIS’ Power Kit minimizes turbo lag by replacing the OEM turbocharger with a larger, more efficient assembly. Use of pulse matching technology, like that found in twin scroll designed turbochargers, allows higher air flow rates at lower engine speeds. High flow fuel injectors allow sustained wide open throttle use and a redesigned diverter valve provides long life under high temperature conditions."

http://www.stasisengineering.com/Cat...VID=48&PID=192


I found a confirmation from AWE that S3 K04 is not twin scroll

[jayphil82]

Very interesting! But is there a tune out there?

Unitronic has a tune for 950$.

[swoardrider]

The S3 K04 uses a "divided" manifold, which "acts" like a twin scroll. There have been many threads on forums regarding whether the S3 K04 is twin scroll. Part of the confusion is that there are quite a few Audi released literatures on the S3's technology, and in them they say the S3 uses a twin scroll turbo. But, Todd at AWE confirmed a couple of years back that they are definitely not twin scroll by disecting a few. I remember that he also posted a diagram of the manifold showing the divides in the manifold. I think this discussion was on VW Vortex.

[jayphil82]

I just posted more detail / parts for the custom DV relocation and added intake manifold gasket to the kit.

Anyone have the mesurements of the following items I just want to make sure I pick the right size silicone hose/coupler:

• Intake to Turbo Inlet pipe
• Turbo Inlet
• Turbo compressor outlet to intercooler
• Engine (trottle body)

They are probably around 2.5" but I want to make sure!

[baldy]

Would the turbo outlet/DV relocation work on our cars from AWE tunings kit?

http://www.awe-tuning.com/pages/shar...n&IL=mk5k05kit

[greensto]

Please keep this thread going :)

[bloodstar57]

Will the internals on the s3 K04-064 fit inside a K03? I have spare K03 (b7) that i have disassemblied and want to fit the k04-064 internals inside to avoid most of the custom work

[Satummoo]

Will the internals on the s3 K04-064 fit inside a K03? I have spare K03 (b7) that i have disassemblied and want to fit the k04-064 internals inside to avoid most of the custom work

wondering this too, seems like it would be cheaper and easier

[Sales@RAI]

Will the internals on the s3 K04-064 fit inside a K03? I have spare K03 (b7) that i have disassemblied and want to fit the k04-064 internals inside to avoid most of the custom work

It's not that easy

[bloodstar57]

It's not that easy

How much milling and honing is need?

[baldy]

OK Guys, Time to bring this thread back to life...

I went through the list of parts up top, and went through ETKA, spoke to a couple guys that have done this in the past, and have now compiled a list of what's neccessary.

Turbo is @ CTS (They just got a shipment of these in, so if you want to do this now is your chance),
Injectors are in my hand (thanks to Chris...member on here),
All the misc. hardware parts have been ordered from Zeb at 1stvwparts.com (best price and service I have found, after comparing everywhere)...Thanks Zeb. (Zeb also has this list saved if any of you guys are going to do this as well to save you the hassle of typing everything in)

Car goes to CTS around the 17th (or sooner, depends when it's back from the body shop and dealer....long story... let's just say there was a fire, and due to the fact of aftermarket parts being on the car, Audi bowed out graciously and I was left to deal with insurance), will get Unitronic tune and everything fabbed up that is missing for a complete kit. I'll post up some updates when the build is under way, and the completed install.

So without further ado, here's the list of what's needed to make your install go smoothly and look OEM..



Injectors / install kit and Intake Manifold Gasket
TTS / S3 Injectors- 06F906036F 4X
Injector Install Kit 06D998907 4X
Gasket - Intake Manifold 06F129717D 1X

Turbo Installation Kit
K04 S3 Turbo- 06F145702C 1X
Exhaust Manifold Gasket- 06F253039F 1X
Breather Tube Gasket 06F145757F 1X
Stud-Priced Each (10x28) N0445203- 4X
Turbo Oil Line Sealing Washer N0138514 2X
Turbo Coolant Sealing Washer 2X
M8 - Self Locking Nut N90894601 5X
Hex Nut - Self Locking N10286108 4X
Oil Return Gasket 06F145757H 1X
Oil Line 06F145778G 1X


Flange that will need to be welded to the Testpipe or HFC
Turbo Downpipe Flange- ATP-FLS-071 1X
OE Turbo To DP Gasket 1K0253115K 1X


DV Relocation
DV Relocation Flange- 06F145751 1X
DV Flange Bracket 06F145383L 1X
Hose for DV rel. 1K0145845A 1X
Hose for DV rel (around v cover) 1K0145693B 1X
Custom "BOV" T pipe Custom 1X
1" Hose Clamp- CLC-CLA-015 4X

WIRE SET (dv relocation) 000979133A 2X
WIRES (dv relocation- 000979134A 2X
HOUSING to DV Connector 1J0973722 1X
HOUSING to harness Connector 8D0973822 1X


Grand total for all the parts including my tune upgrade will be $2061.11.

Parts to fab 3" downpipe, and DV relocation T's
3" Vibrant V-band
3" (6" length) Stainless turbo-flex from Vibrant
3" Stainless pipe (5 feet)
2.5" to 2" silicone reducer from Vibrant
1" bung for DV
1.5" bung for DV on TB side
2.5" 90 degree aluminum pipe (x2) for turbo outlet
2.5" aluminum pipe (1 foot straight) for turbo outlet

Total $220




What has been fabbed to have a complete kit

o Custom Intercooler piping since the compress outlet is not in the same angle than the K03
o Custom work (welding of the flange, grinding of manifold ridges) all this is minimal
o Turbo inlet pipe with bung for the DV relocation hose
o Unitronic tune http://unitronic-chipped.com/imgs/dy...20l_tfsi_1.jpg

1.) The turbo exhaust flange on a K04 and K03 are completely different. So, the A4 downpipe will NOT bolt up to this turbo and a custom downpipe will have to be made that incorporates a S3 (or GTI) flange. This does not apply to transverse engines.
2.) The manifold will not seat properly to the head unless the appropriate ear of the exhaust flange is trimmed (it will hit the motor mount). This does not apply to transeverse engines.
3.) The compressor outlet and inlet of the turbo are in different locations than an A4. You would need custom hoses to make this work. This does not apply to transeverse engines.
4.) K03s have a DV that's incorporated into the turbo where as the K04 has no provisions for this. So, your custom compressor outlet hose will also have to have a bung for a DV. This does not apply to transeverse engines, as you can purchase OEM parts to complete this.

Why didn't I go the APR route? Because I already have a tune, HPFP, and injectors and couldn't justify the price...
Why didn't I go RAI? I really wanted to, honest, but there wasn't enough feedback to take the plunge.. I'm sure it's an awesome product, and makes more power than the K04 will, but I have a TIP and just wanted to be cautious.. Maybe unjustified, but I've heard that even an agressive tune can take out the clutches and torque converter with the K04 (not to mention bend rods) so I didn't want to chance it...

[makav3li]

awesome writeup, thanks for the update, very informative!

[ZEBLOR]

Great job Peter!

[AudiCoupe]

Nice to see that someone else is going down this route.
I promise you you will not be dissapointed with this turbo upgrade. I'm loveing every minute of driving with the K04. Stock driveability and reliability but with more power.
Perfect upgrade in my mind.

Let me know if you run in to problems and I'll try to help you out!

[RedS-line]

good luck to you. ill be rooting for you to come out with a nice little beast. it will probably be worth starting a new thread for. but you cant possibly have all the parts AND the tune for $2020 right? i mean the tune is 700 and the turbo itself is around 1200 so i cant figure out how you got that number....

[baldy]

All of the misc parts above (minus the turbo and injectors) comes out to around $400. The tune upgrade from my Unitronic stage 2 hpfp is 75$... Injectors I bought from a member here for $300.. But apparently there is a guy on ebay europe that sells them for 250 (which would lower the price to under 2k).

So that's how I got the magic number... Sounds appealing now to upgrade doesn't it?

[Operator]

All of the misc parts above (minus the turbo and injectors) comes out to around $400. The tune upgrade from my Unitronic stage 2 hpfp is 75$... Injectors I bought from a member here for $300.. But apparently there is a guy on ebay europe that sells them for 250 (which would lower the price to under 2k).

So that's how I got the magic number... Sounds appealing now to upgrade doesn't it?

It does, but I've yet to find this guy on ebay that sells S3 injectors for $250, and I looked mighty hard. And there aren't alot of Unitronic guys so the $75 tune won't be for everyone. Not, trying to be a downer at all, because I love watching everyone mod there car, and seeing the transformations. I just don't want newer users to read the thread and think, "awesome I can go K04 for less than $2k." And it also seems like you a getting a decent amount of fabrication done to fit it all (pretty much your steps 1-4), and that will also increase the price. Even still, I'm looking forward to your completion and review. If you have the time, post up a build thread, with all your mods. Oh and A+ for being another TIP to take it up a notch!!!!!!!!!!!!!!!!! Looking to join you soon!

[Satummoo]

It does, but I've yet to find this guy on ebay that sells S3 injectors for $250, and I looked mighty hard. And there aren't alot of Unitronic guys so the $75 tune won't be for everyone. Not, trying to be a downer at all, because I love watching everyone mod there car, and seeing the transformations. I just don't want newer users to read the thread and think, "awesome I can go K04 for less than $2k." And it also seems like you a getting a decent amount of fabrication done to fit it all (pretty much your steps 1-4), and that will also increase the price. Even still, I'm looking forward to your completion and review. If you have the time, post up a build thread, with all your mods. Oh and A+ for being another TIP to take it up a notch!!!!!!!!!!!!!!!!! Looking to join you soon!

It was ebay.uk that the s3 injectors were selling for 250$. I looked a few months ago and found it, but recently I can't find it on their

[Operator]

In July I started looking at eBay uk, eBay de, and any other euro eBay site and I never found the $250 set. There was some guy in an Eastern bloc country selling a set, but for more than two fifty.

[solaris10]

This is a link to my attempt at this conversion

[golfvdude]

Awesome!

[Cosworth]

Don't forget the S3 cam, since our cars have an extended warranty on cam, cam follower, fuel pump ect... when you have your car in the dealership to get them replaces ask the parts guy if there is a difference in price for an S3 Cam.

It will help the engine breath better at higher RPM's

just my .02

[solaris10]

My next step is fit the S3 inlet and exhaust cams along with internals and dropping the compression. Hopefully I can kick out some good figures as a result.

[baldy]

OK, so the car is almost done at the dealership and will be heading tomorrow to the shop for the S3 K04 transplant to begin. My only question is to those that have done this, will the oil and coolant lines fit from the K03 on to the K04, or do I need to order the K04 ones. I don't know how I looked this over, so hopefully they can be re-used.

Anyone>?

[AudiCoupe]

OK, so the car is almost done at the dealership and will be heading tomorrow to the shop for the S3 K04 transplant to begin. My only question is to those that have done this, will the oil and coolant lines fit from the K03 on to the K04, or do I need to order the K04 ones. I don't know how I looked this over, so hopefully they can be re-used.

Anyone>?

I reused the mine but they do need to be bent to fit the K04. If you do bend them to fit be carefull not to crack them!

[solaris10]

OK, so the car is almost done at the dealership and will be heading tomorrow to the shop for the S3 K04 transplant to begin. My only question is to those that have done this, will the oil and coolant lines fit from the K03 on to the K04, or do I need to order the K04 ones. I don't know how I looked this over, so hopefully they can be re-used.

Anyone>?

Same here, I bent my existing oil and coolant lines to fit, you'll will need to order the s3 breather hose that connects to the valve cover.